CAD LAB

Assignment 6

In this assignment we will model a complex forging analysis using ABAQUS. A rectangular
billet is forged using a rigid die with large corrugations as shown in the Figure. The billet
metal has Youngs modulus of 2.E+11 N/m 2 and Poissons ratio of .3. It has a yield stress of
1.E+8 N/m2 and a linear hardening modulus H = 3.E+8N/m 2. An axisymmetric analysis is
performed and the die is modeled using an analytical rigid surface with the dimensions as
shown in the figure. Penalty contact is defined between the billet surface and the inner
surface of the die. The bottom of the billet is constrained in the vertical direction while
axisymmetric conditions are imposed along the line of symmetry which coincides with the
left edge. The die is pushed downwards with a constant velocity of 20 m/s. This velocity is
sufficiently slow to allow quasi-static simulations to be performed with ABAQUS/Explicit.
The large plastic strains result in severe distortions in the mesh and the Lagrangian simulation
cannot complete. To allow the analysis to complete, the Arbitrary Lagrangian Eulerian (ALE)
capability in ABAQUS has to be activated. With this background, first try performing a
Lagrangian analysis. Run the job for .0035 seconds. Note where and why the excessive
element distortion messages, that cause the analysis to abort, appear. Why does excessive
element distortion result in the analysis aborting? Next perform an ALE analysis with mesh
smoothing frequency of 5 and 3 mesh sweeps per increment. Does the job run to completion
with ALE? Why is it necessary to extend the analytical rigid surface to the right, much
beyond the original billet length of 200 mm? Where do the maximum plastic strains occur
and what are their magnitudes? What mesh size did you use for a billet? An excessively
coarse mesh may result in even the ALE analysis failing to complete.