1.

SHAPE ROLLING TEMPLATE 1-0

1.1. Creating a New Problem 1-0
1.2. Layout of Shape rolling template 1-1
1.3. Defining the Rolling Process 1-2
1.4. Roll Pass Design Setup 1-7
1.5. Defining Workpiece/Stock. 1-8
1.5.1. Defining Workpiece/Stock Geometry 1-9
1.5.2. Generating Mesh for Workpiece/Stock 1-10
1.5.3. Defining Material & BCC for Workpiece/Stock 1-11
1.6. Defining Rolls 1-12
1.6.1. Defining Geometry for Roll 1-12
1.6.2. Defining Material & BCC for Roll 1-15
1.6.3. Defining Angular Movement for Roll 1-16
1.7. Defining Inter-Object Relations 1-17
1.8. Defining Inter-pass heat transfer 1-19
1.9. Defining a Second Pass 1-21
1.10. Running the Simulation and Post-Processing 1-25
1.11. Exiting DEFORM-3D 1-25
1. Shape Rolling Template
1.1. Creating a New Problem
On a Unix machine, type DEFORM3 to open DEFORM-3D. On a Windows machine, go to
the button and select DEFORM-3D from the menu. The DEFORM-3D MAIN window
will appear, as shown below. Make a new problem under Problem directory. The problem
setup window will open.
Select the shape rolling guiding template as seen below and click .
Select under problem current directory in the problem, name the simulation SHAPE_ROLL_Lab2
and click Finish.
Figure 1: The problem setup window.
Figure 2: The problem setup window.
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Figure 3: The problem setup window.
1.2. Layout of Shape rolling template
The layout of the interface can be seen in the figure below. The screen is distributed into four
discrete sections. The display window is where the objects for the current operation can be
viewed. The project list window is where the list of settings currently editable. Based on the
selection in the project list window, certain values can be edited in the setting modification
window. As information is provided to the interface, information will be printed in the project
record window such as saved steps.
Figure 4: The layout of the shape rolling template interface
Select English units for this Lab, while we leave the Project Name & Title to remain defaults as
shown in Figure 4.
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1.3. Defining the Rolling Process
The shape rolling preprocessor will start.
The process setting window, as seen below, should appear on the screen. This window allows the
user to insert operations into the process list.
Add two rolling passes and one heat transfer operation (between two passes) to process (either
drag rolling icon into project view or click add to tree.) Project list window looks like as
shown in Figure 5.
Figure 5: Template showing added operations
You can modify the default settings (See Figure 6) for rolling or heat transfer operation before
adding the operations to the project by clicking on default setting button, these settings would
automatically get modified once the data is input in subsequent operations.
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Figure 6: Default process setting window
Close process setting window. Click on the first operation in the project view dialog and click
open opr button to open the operation. Name operation PASS1" (See Figure 7).

Figure 7: Process of opening first operation and renaming.
Select rolling type as Steady state ALE rolling (see Figure 8). Click Next.
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Figure 8: Setting of method of calculation.
In the thermal calculations page, select the "Calculate temperature in workpiece and rolls (non-
isothermal)" option (See Figure 9). Click Next.
Figure 9: Setting of type of thermal calculation
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In the number of objects page, there are three models such as full, half and quarter model. In this
lab, we will use quarter model option. We will be using main rolls, and the workpiece in this lab.
(See Figure 10)
Figure 10: Setting of type of model.
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Figure 11: The project view dialog with the rolling type selected.
Note: The shape rolling template supports the guided/open concepts used by many DEFORM
products. At any time during the problem setup, the next or back buttons can be used to
navigate to adjoining windows. In addition, the Project View highlights the current position in
the setup at any time.
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1.4. Roll Pass Design Setup
In Roll Pass Design we select to use primitives for main roll pass design (see Figure 12). Select
Round rolls with default dimensions and create the geometry. Create the geometry. The geometry
looks as shown in Figure 14. Click on "Close" button to close the pop-up Roll Pass Design
window. As you see only top roll is created because by default we assume that it is a quarter
symmetry.
Figure 12: User primitive page.
Figure 13: The main roll geometry definition.
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Figure 14: The rolls defined by the selection of roll geometry.
1.5. Defining Workpiece/Stock.
In Number of Objects window, ensure that workpiece and top roll are enabled, and that use
quarter symmetry is checked. (If you uncheck the quarter symmetry checkbox it will generate
cross-section geometry for the bottom die.)
Specify a workpiece temperature of 300 F. Choose the object length type as User defined
with length 20 inches (See Figure 15) and click next to define its Geometry.
Figure 15: Defining workpiece parameters
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1.5.1. Defining Workpiece/Stock Geometry
Select Use 2D geometry primitives for workpiece 2D cross-section (See Figure 16). Select the
cylinder and make the radius 4.0. Create a quarter circle. (See Figure 17).
Figure 16: Selecting the mode of creating 2D geometry.
Figure 17: 2-D geometry primitives in the shape rolling template.
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1.5.2. Generating Mesh for Workpiece/Stock
Use 90 elements in the 2D mesh for the workpiece cross-section and generate the mesh. For the
workpiece 3D mesh, increase the number of layers to 72 and leave all other settings as default and
generate the 3D mesh. (See Figure 18) Zoom in and ensure that workpiece looks as seen in Figure
19.
Figure 18: Mesh Settings for workpiece.
Figure 19: 3-D brick mesh for the shape rolling template.
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1.5.3. Defining Material & BCC for Workpiece/Stock
In Material window, import AISI-1055 data from the DEFORM library.
Figure 20: The Material library window.
Figure 21: The Material selection window.
View the default symmetry conditions & Heat exchange with environment surface assigned. The
default conditions are correct and hence we can go ahead , click Next.
.
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1.6. Defining Rolls
Specify a temperature of 100F for the top roll. Click Next. (At this point, the roll geometry could
be edited, a different geometry imported, or a different primitive selected).
Figure 22: Setting of top roll temperature.
1.6.1. Defining Geometry for Roll
As the roll geometry is already defined, and no changes are necessary, go on to generate the 3D
geometry for the roll with 108 uniform layers as seen in Figure 23. 3D geometry of the roll looks
like as shown in Figure 24.
Figure 23: The geometry generation window.
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Figure 24: Three-dimensional image of the roll geometry.
In geometry surface page, select the symmetric plane as shown in the Figure 23 and select add
to define the boundary condition of the roll. Click next
Figure 25: Selection of symmetric plane.
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Figure 26: Applying geometry condition for roll geometry.
Use 100 elements in the 2D mesh for the top roll cross-section and generate the mesh. For top roll
3D mesh, change the number of layers to 72, leave all the other settings as default and generate
the 3D mesh.
Figure 27: The mesh generation window.
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Figure 28: Three-dimensional image of the roll geometry with mesh.
1.6.2. Defining Material & BCC for Roll
In Material window, import AISI-D3 data from the DEFORM library.
Figure 29: Material selection window.
Click Next will take you to the BCC page .
In BCC Page select select symmetry BCC and select symmetry Surface as shown in Figure 30. By
default Heat exchange with environment is defined to all surfaces including symmetry surface
which is not correct, Hence delete the default definition and select all the surfaces except
symmetry surface shown in Figure 30 and then click button. Click Next
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Figure 30: Assigning Symmetry BCC
1.6.3. Defining Angular Movement for Roll
Figure 31: The display page showing the direction of assigned angular velocity.
Assign a constant angular velocity of 55 rpm for top roll. (See Figure 31) Click Next.
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1.7. Defining Inter-Object Relations
Object positioning is not required at this stage of the lab setting.
In the Generate inter-object relations page (master-slave relations will be automatic). Go to edit
page, define the coulomb factor as 0.7 and interface heat transfer coefficient as 5.Click on
for contact generation tolerance. Select the Generate all button. The Generated contacts looks
as shown in Figure 33.
Figure 32: Inter-object relationship window.
Figure 33: Contact generation between roll and workpiece.
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After inter-objects relations, go to step controls and stopping criteria. Set 5000 time steps for this
simulation with a step increment of 25.Set TIME PER STEP value to .001.
Figure 34: Step controls.
Check the data and generate the database. Close operation 1.
Figure 35: Generate database window.
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1.8. Defining Inter-pass heat transfer
Highlight the second operation (which is a heat transfer) and click Open opr. You will see
automatically generated workpiece (Figure 36) with uniform cross-section. (It uses the
approximate exit cross-section of the first pass. But in during run it uses the actual exit cross-
section to generate workpiece for heat transfer operation.)
Figure 36: Workpiece generated for heat transfer operation
Object positioning is not required for heat transfer operation.
Go to Heat Condition page and input transfer time as 10 sec and environment temperature as 68F. Use
other default values.
Figure 37: Setting of heat transfer time.
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Go to Step Controls page and put 10, 2 and 1for Number of steps, Step increment and time per
step respectively. Close the heat transfer operation.
Figure 38: Setting of step control for heat transfer.
A window as shown in the figue below would pop-up after closing the heat transfer operation, click yes.
Figure 39:Pop-up window.
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1.9. Defining a Second Pass
Highlight the third operation and name it pass 2. Click next until you reach Roll pass design
page and select the Use primitives for main roll pass design.
Select Flat type rolls and change the dimensions of roll gap to 6.5.Leave all the other settings as default.
Create the geometry.
Figure 40: The main roll geometry definition.
A 2D sectional representation of the roll gap should be visible in the preprocessor as seen in
Figure 41.
Figure 41: The rolls defined by the default selection on roll geometry.
Since we are using the same workpiece no need to create a new geometry, rotate the workpiece
by selecting the option in workpiece or object window as shown in the figure below
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Figure 42: Rotation of workpiece by 90 .
Defining roll geometry:
Specify a temperature of 100 F for the top roll. (At this point, the roll geometry could be edited,
a different geometry imported, or a different primitive selected). As the roll geometry is already
defined, and no changes are necessary, go on to generate the 3D geometry go on to generate the
3D geometry for the roll with 108 uniform layers as seen in Figure 43. . Click next and select
symmetry as shown in Figure 44. Click next
Figure 43: Three-dimensional image of the roll geometry
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Figure 44: Assigning symmetry BCC
Generate 2D Mesh with 100 elements and 108 layers for 3D mesh. Generate Mesh, the mesh
looks like as shown in Figure 45. Click Next.
Figure 45: Three-dimensional image of the roll geometry with mesh.
In BCC Page select symmetry BCC and select symmetry Surface other than the surfaces shown in
Figure 43. By default Heat exchange with environment is defined to all surfaces including
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symmetry surface which is not correct, Hence delete the default definition and select the surfaces
as shown in Figure 43 and then click button. Click Next
In Material window, import AISI-D3 data from the DEFORM library. Assign a constant
angular velocity of -55 rpm for top roll and move the top roll up by 0.25 as shown in Figure 47
Figure 46: Positioning the top roll downward for 2
nd
pass
After assigning the position a pop-up window would appear on the screen, click yes as shown in the below
figure.
Figure 47:Pop-Up window
In the Generate inter-object relations page (master-slave relations will be automatic). Define the coulomb
factor as 0.5 and interface heat transfer coefficient as 5. and click on for contact generation tolerance.
Select the Generate all button.
Use the same step definition settings as for pass 1. Close the operation (master file will save when
operation is closed). Close out of the shape rolling template. Start the simulation.
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1.10. Running the Simulation and Post-Processing
Exit the shape rolling template. In GUI main select the DB & under simulator click on
Run. The simulation will be started. Simulation Graphics to see the results simultaneously as
simulation runs. Post-Processor can be used to view the results.
1.11. Exiting DEFORM-3D
Click the Exit icon. Once you are back in the MAIN window, you can exit DEFORM-
3D by selecting FileQuit or by clicking . When asked whether you want to quit, click
.