Papers by Keyword: DEFORM-3D

Abstract: The goal of this research is to examine the influence of temperature affects the forging of a rectangular billet of AISI 4120 alloy steel using the 3D Deform version 11 software. The simulation was performed with 0.3 coefficient of friction on a metal forming (lubricated) process and the part is intended for application in aerospace and oil and gas industries. Three modules of deform software were defined to execute the simulation: pre-processing, simulation, and post-processing. The pre-processing in forging employed standard data— material selection, billet drawing, top and bottom dies design, meshing and simulation control. After 120 steps, the post-process estimation of deformation temperature, effective strain and stress, total velocity, and total displacement were obtained on the billet of material at temperatures of 800^o C, 1000^o C, and 1200° C. The results show that when forging temperatures climb, effective strain and stress decrease, total displacement and velocity decrease, and the final temperature increases.

Abstract: There is a growing demand for more efficient and economic manufacturing process to improve product quality, reduce production cost, reduce lead time and increase productivity. The application of computer aided design and manufacturing (CAD/CAM) techniques to forging is becoming increasingly popular as the resulting improvements in yield and productivity. Modeling and simulation have become a major concern in recent and advanced research. In this paper die design for forging of an automobile component “Stub Axle” is presented. In die forging process, complex shape component cannot be made in one stage and therefore, the use of preform die becomes essential. The initial preform design was carried out by conventional method. The simulation has been carried out using software DEFORM-3D. The main goal of this study is to design an optimal preform shape resulting an optimal initial billet selection. Keywords:CAD/CAM, Preform, DEFORM-3D, Simulation, Forging

Abstract: In order to research the ploughing extrusion angle influence on cutting performance and realize the virtual design and manufacture of ploughing-extrusion forming cutter, the plough-extrusion forming process of wick micro-groove structure was simulated by DEFORM-3D software. The micro-copper tube with diameter of 6 mm was simplified to 0.4 mm thick copper plate in this paper. In the simulation process, only the single parameter of tool extrusion angle was changed (45^°, 60^°, and 90^°). The structure, stress and strain distributions of copper plate fins formed by three kinds of extrusion angle cutters were analyzed. It is concluded that the plough-extrusion cutting performance of 60 degree extrusion angle cutter is the best.

Abstract: In aluminum foil rolling, the secondary particles may lead to stress concentration at the boundary between these particles and the matrix. Different types of particles would result in stress concentration at different levels. The three dimensional finite element modeling (3D-FEM) was used to simulate the effect of the particles with different hardness on mechanical properties of the matrix of AA1235 aluminum foils in its foil rolling process. The hardness ratio was used to evaluate the mechanical property of foils. It has been found that when the hardness ratio of the particle was similar to that of the matrix (R=1), the interaction mechanism of the dislocations with the particle was dislocation cutting way. When the hardness ratio of the particle to the matrix increased from 1 to 6, the interaction mechanism of the particle with the matrix changed from the dislocation cutting way to the Orowan dislocation bypass way. When the hardness ratio increased to as high as 6, dislocation interacted with the particle only by the Orowan dislocation bypass way.

Abstract: Nuclear grade 316LN austenitic stainless steel (ASS) with an exceptional combination of mechanical properties and corrosion resistance was used to produce AP1000 primary coolant pipe. In order to evaluate the microstructure evolution of the pipe during its forging process, the material database of the 316LN ASS is established with high integrity and reliability. In this paper, the thermal physical parameters, flow stress-strain data and the recrystallization kinetic equations of the 316LN steel are coupled, and the material database is systematically established. Most important, the reliability of the database is verified by an experiment.

Abstract: The paper presents the software and data transfer method between ProCAST and Deform-3D, which allow to take into account the geometry, temperature, residual stresses and microstructure of semi-finished product in the “casting – forming” processes.

Abstract: Lateral extrusion, sometimes called injection upsetting, offers a product with central boss section having complete or segmented protrusions. Collar flanges, spur gear forms, spline or taper with shaft are examples of the products of produce by lateral extrusion. The aim of this study is to investigate the lateral extrusion of gear-like spline form in terms of forming load and load die filling ratio and comparison the results with those results obtained from a commercially FEM based programme named DEFORM-3D. A series of experiment has been carried out using solid lead billets with two different billet diameters and two different billet heights. Experiments were carried out by using a hydraulic press of which capacity 150 metric tons. Load-stroke relations and die filling ratios are obtained both theoretically and experimentally. It is obviously shown that the results obtained from the DEFORM-3D could be used for simulating of the deformation process.

Abstract: Ti-50.8%Ni shape memory alloy was subjected to four passes equal channel angular pressing (ECAP) with angle 120◦ via route B_c at 450°C. The deformation homogeneity was analyzed on planes across the thickness of the deformed sample by Deform-3D software. Two methods were used from the simulation model to quantify deformation homogeneity , including strain standard deviation (SSD) and inhomogeneity index (C_i). In addition, The deformation heterogeneity of ECAP was analyzed experimentally from microhardness inhomogeneity index ( HII) based on Vickers microhardness test results.In the present work, C_i and SSD had been testified to detect which one could give better results experimentally. It was demonstrated that the simulation results of SSD measurements were in good agreement with experimental results .

Abstract: In this paper, based on electric quenching production process in rail and beam factory of Baotou steel, using the finite element software DEFORM-3D, with 60kg/m U75V rail as the prototype, established a three-dimensional model of rail residual heat quenching to simulate and calculate evolution law of tissues and stress on rail head in quenching cooling process in quenching unit, and provides a theoretical basis for finding reasonable optimal cooling rate of rail head in the rail online residual heat quenching process.

Abstract: Based on the software of Deform-3D , the finish rolling process of H-beam has been simulated. According to the simulation from result , in the finishing process ,the residual stress of large sized H-Beam is mainly caused by uneven deformation. The big deformation exists in web. The flange deformation is only generated in the rolling surface. This uneven deformation leads to big residual stress in rolling piece.