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Table of Contents
1.1. Drawing Lug ............................................................................................................................... 3
1.1.1. Description of the simulation model ...................................................................................... 3
1.1.2. Detailed description how to simulate the process ..................................................................... 4
1.1.2.1. Analysis 1: Cooling of the billet ................................................................................ 4
1.1.2.2. Analysis 2: Chamfering .......................................................................................... 16
1.1.2.3. Analysis 3: Pre-forming .......................................................................................... 26
1.1.2.4. Analysis 4: Final forging ......................................................................................... 36
1.1.3. Postprocessing ................................................................................................................. 41
1.1.4. Final remark .................................................................................................................... 49
1.2. Support Arm .............................................................................................................................. 50
1.2.1. Process Description and Objective of the Simulation .............................................................. 51
1.2.2. Model Description and Idealization ..................................................................................... 51
1.2.2.1. First step of forge rolling of the billet ........................................................................ 51
1.2.2.2. How to set up the simulation ................................................................................... 54
1.2.2.3. Finish forging ........................................................................................................ 74
1.2.2.4. How to run the simulation ....................................................................................... 74
1.2.2.5. How to transfer the bent workpiece to the final forging step ........................................... 75
1.2.2.6. How to postprocess the simulation ............................................................................ 78
1.2.2.7. Remarks ............................................................................................................... 82
1.2.2.8. Conclusions .......................................................................................................... 82
1.2.2.9. Exercises .............................................................................................................. 83
1.2.2.10. Further reading and Information .............................................................................. 83
Drawing Lug
Unit
mm
A new object is created in the Object tree.
As soon as it has been assigned to the Process tree it is visualized in the Model window.
Assign it to the Workpiecein the Process tree.Select the material 42CrMo4_h1 from the Material library and
assign it to the workpiece of the process tree.
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Check the process tree and make sure it is complete as shown in the following figure:
After this positioning operation the workpiece is intersecting the upper die and is not in contact to the lower die.
Translate the Upper die by 100 mm in positive Z-direction, so that it is not interfering with the workpiece. Then
call the Positioner for the workpiece, save the project as asked to do so and position the workpiece along the Z-axis
with the Type Default positioner by clicking on
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Finally, the stroke and the Sub-stages must be set: To do so, please measure the z-distance with the Measuring tool
from the bottom edge of the upper die to the upper edge of the lower die The the stroke must be defined so that the
final distance is 22.5 mm. Open the Forming control (FV) by double mouse click on Forming in the process tree
and set the Stroke to 43.446 mm. The Direction is already predefined and does not need to be modified.
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Figure 1.30. Positioner to move the workpiece in contact with the die
Align the tool Die-1 so that it is above the workpiece Billet but in contact with it.
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The Ambient temperature is already predefined to 50C and does not need to be modified.
Please verify if the process tree looks like in the following figure.
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Finally, the Stroke and the output divisions need to be defined: a double click the Forming icon of the process tree
opens the Forming control (FV) for the definition of the Stroke.
Click on Specify stroke... to calculate the stroke with the help of the two previously defined points. For this functionality the distance between the dies after forming must be known. Here, the Distance at 100% stroke shall be 80 mm.
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The resulting stroke is calculated and displayed. It is automatically transferred to the Forming control by clicking
on OK.
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The Finite volume element size can also be controlled in the forming control and should be reduced to 8 mm.
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Use Output divisions to define 21 Equal division of Workpiece / die result steps to be provided for postprocessing
during the analysis. This is every 5% of the analysis progress.
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Postprocessing
1.1.3. Postprocessing
The results of the analysis are imported automatically to the GUI during the analysis run which allows to evaluate
them even during the analysis run. The presence of results is indicated in the project tree by the Resulticon
Basic Postprocessing techniques will be explained in this chapter for the following tasks:
Evaluations of temperatures using animations and plots
Saving of animations and plots
Measuring of result values on the workpiece surface
Displaying of tool forces using diagrams
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Postprocessing
For which point in time during the analysis shall the result be shown: Here 100.00 %
as a result plot:
as a animation
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Postprocessing
Then click on
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Postprocessing
can be used.
Very similarly animations are created. In this example the effective plastic strain shall be shown for the process Preforming in an animation.
First, select the workpiece in the process Pre-forming:
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Postprocessing
Then select the result value, here e.g. Effective Plastic Strain:
Clicking on Animation
displays the animation - please note the tools on the bottom of the animation window
to play, rewind, etc. the animation:
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Postprocessing
The Legend can be adjusted as per user requirements - colors, ranges and many other adjustments can be done. These
settings are opened by the button
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Postprocessing
A click on Flowlines
activates the display of the defined flow lines (here shown in red) and particles (here shown
in blue). The flow lines can be used to check if e.g. the edges of the billet are positioned in an critical area of the forging.
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Postprocessing
Tool forces, among other values, are evaluated by diagrams. To display them the body or bodies to be evaluated
need(s) to be selected in the process tree. Multiple tools (Upper and lower die) can be selected with the help of the
Ctrl-Key. A click on History plot
displays the diagram. The values to be displayed are selected from the dropdown menus on the right hand of the diagram window.
Here the press forces in Z-direction are displayed as a function of the stroke:
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Final remark
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Support Arm
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The geometries of the tool are ready. Next you will create the workpiece geometry. Use the Model > AutoShape
functionality in the inventory window to create a Cylinder shape with:
Radius
36 mm
Height
360 mm
Angle
360
The created shape is the shape of the workpiece at room temperature. To compensate for its thermal expansion during
the heating, use the Heat up... functionality with the following parameters:
Thermal Expansion Coefficient
Preset of Aluminum
Furnace Temperature
475 C
Initial Temperature
20 C
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Depending on the direction of the local coordinate systems defining the rotation axis of the tools, it might be necessary
to change the rotation direction of the press by defining a negative angular velocity.
The next properties to be defined are the friction properties of the tools. Select a manual definition:
Type of friction
Plastic shear friction
Interface friction factor
0.7
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Figure 1.72. Parameters for workpiece imported from first process step
1.2.2.2.3. Bending
Prepare the simulation model for the bending process on your own according to the following information - only steps
which have not yet been carried out in the previous process steps are explained in detail:
Insert an upsetting process (3D, hot forging, 1 press driven die, 2 regular dies)
Import tool geometries using the CAD import functionality from the folder CAD/bending. The T-shaped tool will
be press-driven, the V-shaped will be the stationary die.
Rename the workpiece to workpiece-T475.
Translate the upper die by -20 mm along the Z-axis.
Import the tool geometry of the lower die of the finish forging process (file ff-lowerdie.igs) using the model
from file functionality from the folder CAD/finish_forging and rotate the geometry by 90 around the X-axis,
translate by 100 mm along the Y-axis, then rotate by 14 around the Y-axis and finally move by 20 mm along the
Z-axis until the final forging die is placed behind the bending tools and the position of the workpiece, the bending
dies and the forging dies are aligned:
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X
275 mm
Y
120 mm
Z
30 mm
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The stage control will indicate that the simulation is finished by green color:
1.2.2.5. How to transfer the bent workpiece to the final forging step
Display the simulated shape of the workpiece in the bending process step by means of an animation:
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Figure 1.79. Preliminary position of the workpiece in the finish forging die
Then call the positioner to position the workpiece to its final position touching the die:
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Activate the FinishForging process in the process tree window by a left mouse click.
Select the workpiece only by a left mouse click.
Select 100.00 % from the context menu.
Activate the checkboxes of the results to be displayed in the result selection bar:
Effective plastic strain
Temperature
Die contact
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1.2.2.7. Remarks
To reduce computing times, especially if many variants need to be simulated to determine the correct workpiece
position in the forging dies, the Standard Finite-Volume solver may be used. For validation of the results the user may
want to repeat the simulation with the best position using the Higher Order Finite-Volume solver, which generally
leads to higher accuracy at the expense of higher computing time.
1.2.2.8. Conclusions
This example demonstrates a process chain simulation using the Finite Element and Finite Volume solver. The process
steps have been linked transferring the simulated workpiece geometry and properties to subsequent process steps. The
linkage was carried out by both available possibilities - manually and using the stage control functionality.
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1.2.2.9. Exercises
1.2.2.9.1. Aim of the exercises
If the simulation shows incomplete die filling, repeat the simulation of the final forging step with a different position
of the bent workpiece in the finish forging die. Second, select a workpiece from the bending process step which was
bent more or less than the one already simulated.
This exercise will give you the opportunity to further practice working with Simufact.forming.
1.2.2.9.2. Postprocessing
Repeat the postprocessing steps as described above. Compare the die filling and the upsetting forces.
Were you successful to achieve complete die filling?
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