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01
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1.
1.1.
1.2.
1.3.
1.4.
1.5.
1.6. (DISPLAY)
1.7.
1.8. DEFORM-3D
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1.
1.1.
unix- DEFORM3 DEFORM-3D. Windows-
>
.
.
DEFORM-3D ( )
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, Block
DEFORM-3D. , .
. , .
. -
:
.
.
,
.
(MAIN) .
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1.2.
.
Block. , English
( ).
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1.3.
,
Object 1 Block
.
(Plastic). DEFORM .
.
DEFORM-3D -.STL .
Block_Billet.STL DEFORM3D\V6.01\Labs.
DEFORM.
,
.
, , -
.
. ,
. ,
5000 ,
.
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1.4.
( , \,
) .
/
.
, .
, , ,
.
( : Shift + )
\
,
.
( : Alt + )
,
. ( : Ctrl +
Alt + )
. ( : Ctrl +
8
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X
Y
Z
)
X
.
Y
.
Z
.
, (
) XYZ
. , ,
,
X , Y , Z .
,
Use object coord for
rotation ( ).
YZ
XZ
XY
X (+) (-)
Y (+) (-)
Z (+) (-)
1.5.
.
.
.
.
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1.6.
:
.
.
.
.
.
.
.
1.7.
.
>
Block.KEY.
1.8. DEFORM-3D
2,
.
DEFORM-3D. 2,
, DEFORM-3D
>
10
. ,
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2.
2.1.
2.2.
2.3.
2.3.1.
2.3.2.
2.4.
2.5.
2.6.
2.7.
2.8.
2.8.1.
2.8.2.
2.8.3.
2.8.4.
2.9.
2.10.
2.11.
2.12. DEFORM-3D
11
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2.
2.1.
,
DEFORM-3D.
2.2.
DEFORM . ,
BLOCK BLOCK.KEY .
, , .
.
2.3.
.
12
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.
,
2 3.
2.3.1.
Object 2 Top Die.
. DEFORM3D\V6.01\Labs
Block_TopDie.STL. .
DEFORM ,
, .
. ,
. , , 1
, 0 , 0 ( ).
, 1 .
,
. ,
,
. , ,
.
2.3.2.
Object 3 .
13
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Bottom Die.
. Block_BottomDie.STL.
( ).
.
2.4.
- , .
..
Top Die .
.
.
.
1 /. .
1 in/sec.
- -Z .
?
- ,
. ( )
,
. , ,
.
14
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2.5.
, , ,
, ,
. ,
68F 20C, .
,
. , 68F .
2.6.
.
,
(flow stress). , (
), .
() ( ),
.
, .
AISI-1035.
. , , ,
. , AISI-1035
and, .
, AISI-1035, COLD.
.
e,
Flow stress.
.
, AISI-1035, COLD .
15
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2.7.
, .
. , -1.
, (
).
20. , 20 .
2. .
, .
(Top Die),
.
.
1/3
.
(
).
0.4". 0.4" 0.13".
0.13.
.
2.8.
. DEFORM-3D
:
,
.
16
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,
,
.
,
.
. .
,
.
.
2.8.1.
Block.
, +Z ,
. , +Z
. Top Die +Z
, , -Y
, .
2.8.2.
, .
17
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Block. -Z
.
2.8.3.
, ,
.
Top Die. :
1)
2) .
.
.
.
, .
18
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2.8.4.
.
.
. ,
Top Die. Block .
, Z.
.
19
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:
.
2.9.
.
, , ,
.
.
. DEFORM
. ,
.
, .
(
). ,
.
.
,
, .
, ,
( ) (Cold forming (steel dies)).
0.12.
20
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.
, ()
21
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( )
. , .
,
, .
.
, DEFORM .
0.0112" .
,
.
,
.
:
,
.
, ,
.
2.10.
. FEM
( DEFORM ) . DEFORM,
( ,
, , ..) .
.
. :
(,
).
, , ,
.
,
, .
, (Volume Compensation).
,
.
.
.
2.11.
(Block.DB) , .
.
Block.KEY.
22
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DEFORM 3D.
2.12. DEFORM-3D
3, DEFORM3D. 3, DEFORM-3D
3.
3.1.
3.2.
3.3.
23
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3.4.
3.4.1.
3.4.2.
3.4.3.
3.4.4.
3.5. DEFORM-3D
3.
3.1.
DEFORM-3D.
3.2.
DEFORM , , .
BLOCK BLOCK.DB
.
3.3.
24
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.
.
( ).
.
, .
:
3.4.
DEFORM-3D
25
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3.4.1.
, .
.
(STEP LIST),
.
:
26
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3.4.2.
.
(StrainEffective)
.
.
(Scaling)
.
.
,
.
3.4.3.
DEFORM .
, .
.
.
. ( )
27
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(Tracking Option)
.
,
,
:
:
,
.
.
.
. -
.
28
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3.4.4.
DEFORM-3D
t. ,
Point Tracking
(Hide PointTracking).
.
. .
.
.
.
29
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.
(SLICING) P (Point) - N (Normal) - .
X, Y, Z
.
. X , ,
.
30
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3.5. DEFORM-3D
, .
, DEFORM-3D
31
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4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
4.8.
32
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4.
4.1.
.
. ,
, .
.
, .
,
1/16 .
4.2.
unix- DEFORM3 DEFORM-3D. Windows ,
DEFORM-3D . DEFORM-3D
. ,
DEFORM-3D,
.
DEFORM ( ).
SquareRing
DEFORM-3D.
4.3.
.
33
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, .
1 2.
Object 1 .
Billet, .
. SquareRing_Billet.STL.
Object 2 .
Die.
Top
SquareRing_TopDie.STL.
4.4.
Billet
, ,
. ,
. ,
5000 .
4.5.
1/16 .
,
.
34
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.
(Symmetry plane) X (
). ,
(Plane Information) .
.
(1,0,0) .
.
, ,
. ,
:
35
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4.6.
.
. ,
,
.
( ) (Cold forming (steeldies)).
,
( 0.002),
.
, .
4.7.
:
36
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1) Top Die
/ -Z.
. 1
.
2)
AISI-1045, COLD .
3)
30
Square Ring.
2. Top Die.
,
.
0.06.
0.02 /, .. 1/3 .
.
.
. (Volume
Compensation) . ,
.
, ,
. ,
37
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, ,
.
4.8.
.
,
. 1/16
.
(SYMMETRY DEFINITION).
, .
. .
.
, (SYMMETRY
DEFINITION). , .
,
.
38
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,
.
DEFORM-3D
39
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5.
5.1.
5.2.
5.3.
5.4.
5.4.1.
5.4.2.
5.4.3.
5.5.
5.6.
5.7.
5.8.
5.9.
40
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5.
5.1.
, .
, ,
, . :
- 10 .
.
- 6 2
. .
- .
- 8 .
2D. ,
3D,
3D 1/4 .
5.2.
DEFORM-3D .
,
. , Spike
DEFORM-3D.
5.3.
. Spike
Forging Transfer from Furnace ( ). ,
English .
10 . ,
, . 50
, 0.2 .
. 50,
10.
0.2 . ,
5.4.
, .
, ,
( ,
).
5.4.1.
Object 1 ,
Billet, . ,
41
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2000F.
. Spike_Billet.STL.
5.4.2.
Object 2 , Top Die.
Spike_TopDie1.STL.
5.4.3.
Object 3 , Bottom Die.
Spike_BottomDie.STL.
5.5.
.
, . ,
,
, .
.
DEFORM (Relativemesh)
(Absolute mesh).
Relative Mesh ,
. ,
.
Absolute Mesh ,
. ,
.
(Weighting Factors)
.
.
- -
42
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.
, .
, .
,
. , ,
.
, , .
, ,
, .
, , -
, 2 (Spike_TopDie2. STL).
. 0.08".
, , 0.04".
. Top
Die 2 .
Blow 1 - Top Die
Blow 2 - Top Die
. .
Billet
0.04.
3.
.
43
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5.6.
,
. ,
, .
Heat Exchange with Environment
( ).
.
. ,
.
Heat Exchange with Environment ( ),
,
.
, - 68F,
.
, .
.
. , Heat Exchange
with Environment, ,
.
44
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5.7.
.
AISI-1025(1800-2200F) . .
.
5.8.
, , >
Spike_FurnaceTransfer.KEY. ,
, , .
.
,
, . ,
45
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.
. ,
.
,
.
5.9.
,
. DEFORM-
(Temperature)
3D.
. (Color Bar)
emperature () .
.
46
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,
.
,
6.
6.1.
6.2.
6.3.
6.3.1.
6.3.2.
6.4.
6.5.
6.6.
6.7.
6.8.
6.9.
47
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6.
6.1.
5 .
2 .
. ( - )
.
6.2.
DEFORM-3D . Spike.DB
.
, 50
.
50 .
,
48
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, 68F,
1833 ~ 1989. ,
, Plot Variable ( )
,
(NodeTemperature)
.
6.3.
,
. DEFORM-3D, :
1) ,
. ,
2) , .
, .
.
6.3.1.
Top Die . ,
49
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68F 300F.
,
6.3.2.
Bottom Die . 68F 300F
. Top Die,
,
.
(Heat Exchange with Environment), ,
.
6.4.
.
AISI-H-13, . (MATERIAL LIBRARY)
50
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.
(Descriptions), ,
H-13. (1450F - 1850F)
, ,
.
H-13 .
.
,
H-13 .
H-13 .
6.5.
Bottom Die.
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-Z
6.6.
.
.
-
. ,
, .
(Free resting) .
,
Billet Bottom Die.
6.7.
.
Dwell () 2.
Bottom Die 2 . -0.2 -
, 10 .
10 5. ,
-51. ( -1 to 50),
Spike.DB, .
.
6.8.
, >
Spike_Dwell.KEY. ,
. Top Die
(Dwell),
.
52
.
.
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,
.
6.9.
,
(STEP LIST),
.
, Billet
(Single object mode)
.
. (Temperature)
(State Variable) (Color Bar),
Temperature .
. -51
.
51 60 . Bottom Die
. 2 .
.
53
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7. 1
7.1.
7.2.
7.3.
7.4.
7.5.
7.5.1.
7.5.2.
7.5.3.
7.6.
7.7.
7.8.
7.9.
54
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7. 1
7.1.
.
.
7.2.
DEFORM-3D . Spike.DB
. 60
7.3.
. Forging Blow 1
3. ,
.
,
. 0.06".
1/3 - 1/2 0.025".
0.75" . 30 .
:
.
30
5. Top Die, Top Die ,
0.025".
7.4.
.
55
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7.5.
. ,
. , ..
.
7.5.1.
Billet
.
(Symmetry plane) ,,
( ).
. . BCC
.
7.5.2.
, .
, , (Mesh).
, , (Geometry).
Top Die
.
, , , .
7.5.3.
Bottom Die
.
,
.
56
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7.6.
Top Die
-Z.
. 2
7.7.
.
, .
(Forming heat transfer
coefficient) (Free resting coefficient),
.
. ,
Hot forging ( ).
, , (Forming)
. .
. .
57
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7.8.
> Spike_Blow1.KEY. ,
.
(Volume Compensation warning)
,
. .
7.9.
,
. Billet ,
,
. , -61 90.
(Temperature) (Effective Strain).
. , /
Show Mesh ( ) (
Show Geo ( )
).
, , ,
, , .
58
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,
.
. ,
, Top Die, X , Y
Z Load.
Load-Stroke (-)
59
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, Load-Stroke
. ,
, .
60
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8. 2
8.1.
8.2.
8.3.
8.4.
8.5.
8.6.
61
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8.7.
8.8.
8.9.
8. 2
8.1.
, ,
.
.
8.2.
DEFORM-3D . Spike.DB ,
.
90.
8.3.
. Top Die ,
,
, .
Spike_TopDie2.STL.
.
62
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H-13.
8.4.
,
.
, ,
:
, .
:
(Heat
Exchange with Environment). ,
8.5.
. Top Die
.
Billet. -Z
:
8.6.
,
.
,
8.7.
. Forging Blow 2
4. , 0.25"
.
63
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10. ,
10 0.025 .
8.8.
> Spike_Blow2.KEY. ,
.
.
(Volume Compensation),
.
. ,
. .
8.9.
,
( )
.
, , -90 100.
, .
, .
64
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9.
9.1.
9.2.
9.3.
9.4.
9.5.
9.5.1.
9.5.2.
9.5.3.
9.5.4. 4
9.5.5. 5
9.6.
65
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9.7.
9.8.
9.
9.1.
.
,
. ,
, ,
.
, ,
.
.
9.2.
. DieStress.
9.3.
. Spike.DB (
( 5 - 8) ).
Problem\Spike). 90, 1.
9.4.
.
Die Stress 1. ,
English, , .
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, .
, ,
. -1,
6 1.
1 .
9.5.
( 4 5) .
.
9.5.1.
,
9.5.2.
.
(Symmetry plane),
1)
.
2) Vz = 0 (Velocity)
. .
3) (Force).
Spike.DB, 90,
. t, (Error
Tolerance) 0.1 ( ).
, ,
.
.
(Error tolerance).
, ,
. ,
.
67
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(
) .
9.5.3.
.
(Symmetry plane),
1)
.
2) (Force) ,
.
9.5.4. 4
4 Upper Support ( ) -
68
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UpperSupport.STL.
=
0.15 = 1.
H-13 .
(Symmetry plane)
1)
.
2) Vz = 0 (Velocity) ,
Z.
3) , ,
(Shrink Fit). ,
. , (0, 0, 0) - , Z -
. ,
. ,
. ,
0.004 (Interference).
,
.
, ,
69
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Displacement ()
.
9.5.5. 5
5 Lower Support ( ) .
LowerSupport.STL.
, =
0.15 = 1.
H-13 .
(Symmetry plane)
1)
.
2) Vz = 0 (Velocity) ,
70
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Z.
9.6.
,
.
.
9.7.
DieStress.KEY.
.
, .
9.8.
,
(User-Defined
Object Mode), .
,
.
,
. , ,
.
71
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, .
, .
.
(State Variable),
(Max Principal stress),
.
.
.
Top Die,
Eff. Stress.
Max Min . ,
, ,
.
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10.
10.1
10.2
10.3
10.4
10.5
73
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10.6
10.7
10.8
10.9
10.10
10.11
10.12
10.13
10.14
10.15
10.
10.1
. - - ,
.
, 1999 ,
. ,
- .
74
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- ,
.
:
1/2 .
:
DIN 41Cr4
:
1300C
:
90C
:
4
:
3.8e7 N-mm
:
3000 N-s2/mm
:
0.5
:
10% .
:
25% .
:
35% .
:
45% .
:
,
. ,
. , .
, ,
, ,
.
,
.
10.2
, Link.
: Steering Link
,
10.3
1: :
2: :
3: :
.
IDS_Link_Billet.stl
IDS_Link_Top.stl
IDS_Link_Bottom.stl
.
10.4
. ,
. ,
. , ,
, .
DEFORM-3D :
75
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1) .
, .
2) .
, ,
.
, , ,
,
, .
- ,
.
10.4.1
-
. , - ,
.
2. ,
1/2 , 1.
, , 1,
3 .
,
, , .
.
0.9 0.1
.
.
45 000 . ,
,
.
10.4.2
,
. ,
, , ...
2 .
3, 6.
10 000 .
10.5
1300C 90C.
, - 90C.
, .
10.6
76
(Target Volume).
.. ,
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, .
DEFORM
. DEFORM
. , .
10.7
, 150/
-Z. ,
.
.
10.8
. ,
+x
+x.
10.9
,
11 .
. ( ) .
11.0 .
10.10
77
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40. , 200
. ,
.
/ 0.2 /.
.
,
. ,
.
130 000 - 150 000 , 1GB RAM,
. , DEFORM
140 000
.
RAM 1GB ,
, SW2SP.DAT,
.
10.11
DIN41Cr4 . ,
.
10.12
.
0.3 ( ), 5 ( ,
). .
10.13
. ,
. .
.
.
, .
. DEFORM
.
10.14
. .
, .
.
,
.
.
, , .
78
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, .
,
.
"" .
.
10.15
,
.
.
1: . 4
2: . 10% 3.8e6. 1/2
(1.9e6), 1/2 (1500)
1/2 . 80%.
3: . , ,
1/2 .
4: . 25% (4.75e6), 1500.
5: - 3.
6: . 35% (6.65e6), 1500.
7: 3.
8: . 45% (8.55e6), 1500.
.
79
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(0.2mm),
0.1 /.
11.
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
80
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11.11
11.12
11.12.1
11.12.2
11.12.3
11.13
11.13.1
11.13.2
11.13.3
11.13.4
11.14
11.15
11.
11.1
- ,
1999 .
. ,
.
1/12 (30 ) :
:
- 31.5, - 67
:
DIN C35
:
1230C
:
80C
:
7
81
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:
:
:
:
0.7
9.5
3 seconds
.
11.2
-
. .
, , .
:
3D, , . ,
.
2D, 3D, 3D. 2D
. 3D
2D 3D, DEFORM. 3D simulation,
.
CAD- .
, ,
, ,
.
3D.
11.3
, Gear_Carrier.
: Gear Carrier
: Furnace Transfer ( )
r: 1
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11.4
1:
: IDS_GC_Billet.stl
2:
: IDS_GC_Upset_Top.stl
3:
: IDS_GC_Upset_Bot.stl
, - .
11.5
10 .
9,5 ,
1.
:
0.9
0.0
0.1
0.1
,
1mm. ,
= 1mm = 1.
,
.
, , 1
. ,
, 3, .
( = 3,
= 0.33mm, = 1mm)
,
.
11.6
:
.
: ,
.
11.7
1230C. 80C.
11.8
DIN-C15 ( ).
11.9
270 85 / (1.4
/). (67)
(9.5), 57.5. , , 1500.
, ,
.
83
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, , .
11.10
14 , 0.5 /. = 2.
11.11
.
11.12
11.12.1.
: Dwell ()
: 2
7 , 0.1 .
11.12.2.
,
.
11.12.3.
,
.
. ,
. ,
Free resting (1 )
- . .
.
11.13
84
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11.13.1
: Upset ()
: 3
, .
.
, 100 . 57.5mm.
120 , 0.5/ 10- .
, , 212.5mm 270mm
. - 57.5 , .
270 Z,
, .
11.13.2
, .
11.13.3
, Hot forging (lubricated) ( ) 0.3
Forming () 5.
.
11.13.4
(TargetVolume).
,
.
11.14
: Transfer2 ( 2)
: 4
, . - 3
. 6 , 0.5 /. .
11.15
: Finish ()
: 5
:
: IDS_GC_Finish_Top.STL
: IDS_GC_Finish_Bot.STL
.
.
85
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, 200 .
1.0e6 N.
.
().
.
, , .
, . 1.
1:
2 . ,
(cogging) ( 1),
. .
(. 2).
86
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2:
(Next).
(. 3).
3:
. (
87
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4).
4:
(, CogLab) Finish ().
. ( (Master Data File) MDT) - MST ( ) CogLab.MDT
CogLab.MST ( CogLab).
( , 5);
. ,
/ , {}
. .
88
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5:
( 6). ,
(
) .
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6:
( 7).
7():
7():
( ),
3D- , . ,
. ( QT,
Motif), " deform".
"USER_HT.KEY".
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,
"CogBilMaterial.KEY" .
. USER_HT.KEY ,
. -
.
,
USER_HT.KEY.
.
USER_HT.KEY " ".
( 7), round cornered rectangle (
) / 20, 60
2. ( 7) 100 , 1
14 . Generate Mesh.
, ( 7)
1500 F. (
8), ( 8) ( 8)
.
7():
7():
. ( 8),
25, 15, 15 2. ( 8), 100
, 1 7.
91
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8():
8():
92
8():
8():
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9():
9():
. 2
GFM (4 ).
X ( ) X.
(
). .
, ""
( ).
1 / 200 F. X 0,
(
. , 0.5
.)
( 9 -).
93
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9():
9():
200F 10
.
. ( X,
.) .
,
.
. ,
( 10).
10:
94
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"AddRH" (
). Reheat 1 ( )
( 11).
Heat In (HIn+)/ Furnace Reheat (Reheat+)/ Heat Out (HOut+) (Pass+)
.
11:
, ,
. "Pass +
", 1 (Pass1). (:
.
.)
12:
. Auto-calculation of bites (
) "Yes" Min. stopping distance ( )
18 . "-1"
X. . Bite Heat,
"BiteHT+". "Bite Heat", 10 of simulation steps, 500
( ).
95
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USER_HT.KEY.
5 . 0.004,
13():
13():
96
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14:
15:
-. Finish () , (
Yes ). MDT-,
. (
BILLET.KEY DIE1-2-3-4.KEY NO
/ .)
, .
,
( ):
CogLab.MST, CogLab.MDT
BILLET.KEY
DIE1.KEY, DIE2.KEY (DIE3.KEY & DIE4.KEY ( 4
.)
MAN1.KEY, MAN2.KEY, MAN3.KEY, MAN4.KEY
SPRING.INI ( )
USER_HT.KEY
$DEFORM3_DIR/TOOLS/COG/LABS ( ).
97
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16:
, .
MDT ( MST) Start Simulation( ).
(. 16). "OK" .
"Command/DOS prompt" -.
, .
COG_CTRL3 COG_CTRL.COM UNIX
DEF_CTRL.COM Windows-NT/2000.
0 , Enter.
(CogLab) ,FEM .
, CogLab.DB.
DEFORM-3D .
, ,
Deform-3D, ,
.
( ) "OK".
98