Papers by Keyword: DEFORM

Abstract: In recent years, the oil and gas industries have been developing significantly. In this regard, there was a great need for the construction of main pipelines, which consist of pipes and connecting parts. The production of connecting parts of pipeline has not been studied enough to date. This article describes the process of stamping halves of stamped-welded elbows. During the stamping operation, the workpiece wall is thinned. The process of modeling this operation in a software of modeling by finite element method Deform-3D is described. The place of the greatest thinning of the wall was determined with the help of Deform-3D. The results of modeling and experimental production coincided. The main factors that may influence the degree of thinning were identified. Experimental calculations were performed in Deform-3D with a variation of these factors. As a result of the experiments carried out, the most significant factor was determined and an option was proposed to solve the problem of wall thinning. Solving this problem will help reduce the cost of production by 1.5 times.

Abstract: The main purpose of this contribution is to create a methodical procedure for numerical simulation of the forging process using FEM of a real part, which is produced in three forming operations. Then this process will be realised step by step for creation simulation model in the simulation software DEFORM 3D, where the output data will be calculated on an example forging process on real component. The obtained results are then compared with reality to determine the degree of match between simulation results and real component. The 3D models of dies for each operation as well as some input parameters were obtained from HKS Forge. This company is leading manufacturer of die forging for the engineering industry in Europe. Proposed methodical procedure can serve as a basis for creating additional simulation models that could simulate the wear of these dies during long time of use.

Abstract: In this study, hot ultrasonic assisted machining of Hastelloy-X material was compared using two different finite element software (DEFORM and AdvantEdge). The results obtained from the two software were compared in terms of maximum cutting tool temperature, average cutting force and maximum effective stresses. The simulations were performed in 2D. The results obtained from the two software were compared with the experimental study in terms of maximum cutting tip temperatures.

Abstract: This paper gives an overview of residual stresses problem after heat treatment of large scale forged parts as well as numerical study and simulations of different methods to reduce stresses. DEFORM software was used for Finite Element Method (FEM) simulations as one of the most capable simulation tools combining both forging and heat treatment processes analysis. The study is performed on the sample of large scale airspace part of aluminum AK6 (AlMgSiCu) alloy. The comparison of different quenching media is presented. Practical conclusions and recommendations are made to optimize the process and reduce residual stresses after the heat treatment. This paper provides numerical simulation and theoretical conclusions and needs to be amended by experimental measurement of residual stresses by one of available methods as part of the future work.

Abstract: The existing process of 2A12 aluminium alloy piston is cutting completed by hot- drawing pole , as a material utilization rate less than 40%. In order to improve material utilization, cold-extrusion process is the reasonable choice, but only if solve the annealing before cold-extrusion, surface lubricated, the Parameter optimization of cold-extrusion and quenching process after extrusion. This research uses the DEFORM finite element analysis and a good effect in practical application is obtained to enhance the rate of more than 80% material utilization, scrap rate is less than 0.5%.

Abstract: In this paper a computer modeling using program complex DEFORM of various models of equal channel angle pressing is made. Also there is a description of opinion of ECA-pressing called “ECA pressing with quasi-ultra-small angles of joint channels” and shown advantages of this opinion.

Abstract: In this study, the true working conditions of a warm extrusion die was simulated using DEFORM-3D software; images of the die’s temperature, stress, and wear distributions were obtained, the amount of wear of the die cavity were calculated, and the wear depth curves were drawn for each test point on the basis of this simulation. A production analysis along with the simulation revealed the main forms of early failure for the warm extrusion mold to be cracking failure, collapsing failure, and wear failure. Through data analysis, the areas of the die that cracked easily or showed heavy wear were identified. The steps required to prevent early failure are proposed in this article.

Abstract: Based on a modified form of Archard’s wear theory, significant data were obtained using the finite element analysis code DEFORM during the process of warm extrusion, including instantaneous interface temperature, sliding velocity, and interface pressure distribution of every node. From the acquired data, the wear of the punch, the temperature–wear coefficient curve, temperature–wear depth curve, and temperature–hardness curve were acquired. The results show that the maximum wear occurred in the front working tape of the punch. The results are in agreement with actual conditions, and therefore, lay a foundation for forecasting die life and optimizing die cavity profiles using this method.

Abstract: DEFORM is a software used for FEA (Finite Element Analysis) simulation. By using this software, I take a research on the procedure when a steel billet with defect of artificial loosening is drawn out in a simulated environment. Then I build a FEA model about the loosening and compaction of a large-sized rotor and stimulate the procedure in accordance with current craft card involving rotor forging. Finally, I get a result: the relative density of the loose area reaches up to 85% after the first drawing-out process (note: forging ratio 1.47). After simulating the procedure of chamfering on a billet which has been already drawn out, I found that chamfering had little substantial impact on the its loosening and compaction.

Abstract: An entire forging process for heavy long-axis forgings was divided into three steps：squaring, stretching, chamfering and rounding. Researches of forging process are now focused on the optimization of stretching, but the effect of squaring or chamfering and rounding on the forging quality is neglected. This article is in view of the problems that titanium alloy heavy long-axis forgings were prone to crack and forging process parameters were not easy to control in squaring. Using the Deform software, from strain, damage, forging required load it analyzed that the fillet radius of V-shaped anvil edge influenced quality of titanium alloy heavy long-axis forgings of different diameters in squaring, then we concluded the best combination between diameter of titanium alloy heavy long-axis forgings and fillet radius of V-shaped anvil edge. It provides basis for improving the quality of this kind of forging in squaring.