4.SQUARE RING 4.1. Introduction 4.2. Creating a New Problem 4.3. Creating New Objects 4.4. Meshing the Billet 4.5. Setting Boundary Conditions 4.6. Inter-Object Relationships 4.7. Finishing Setup and Running Simulation 4.8. Post Processing . . type DEFORM3 to open DEFORM™-3D.2.DEFORM™-3D labs 4. Furthermore. The DEFORM-3D MAIN window will appear. The square ring has quite a bit of symmetry that can be taken advantage of. In this lab. This lab will show you that the deformation of the entire ring can be determined by only modeling 1/16 of its full geometry. On a Windows machine.1. go to the button and select DEFORM-3D from the menu. the smallest possible section that adequately describes the problem should be modeled. we will simulate the upsetting of a square ring. 4-1 . Introduction Symmetry should be taken advantage of whenever possible in simulations. Doing so saves computational time and can increase solution accuracy. Creating a New Problem On a unix machine. SQUARE RING 4. 4. In the field for Problem Name.STL in the and buttons to DEFORM3D\V6_1\Labs directory. View Fit can be used to fit both objects in the DISPLAY window. Highlight Object 2 in the Object Tree. Creating New Objects To simulate the forging of this square ring. . click 1 and 2.STL in the and buttons to DEFORM3D\V6_1\Labs directory.3. . Click on the button and change the Object Name and to Billet and the Object Type to Plastic. Click opening a new problem using the DEFORM-3D pre-processor by clicking to define the location of the new problem 'Under problem home directory'. Meshing the Billet Highlight the Billet in the Object Tree. 4.4. and then click the Controls. The geometry is located in the file SquareRing_Billet. Define the billet's geometry by clicking then . . Click on the button to bring up the Meshing button to see what the surface mesh looks like when using the default mesh settings. click once to add Object 2. The surface mesh that is created looks good. Click button and change the Object Name and import the file SquareRing_TopDie.the bottom die is not needed due to symmetry. Click on the to Top Die. Accept the default setting of . twice to add Objects Highlight Object 1 in the Object Tree.DEFORM™-3D Labs Create a new problem by clicking the New Problem icon. only a workpiece and a top die are required . Use the check the geometry. call the problem SquareRing and click DEFORM-3D Pre-processor will open. The 4. so click the 4-2 . If Object 1 does not exist. If Object 1 does exist. Use the check the geometry. Click on the button to look at the Boundary Condition options.DEFORM™-3D labs button to finish the meshing process. When the meshing is complete.5. the object should have around 5000 elements. Select the Symmetry plane option and then select the surface that is normal to the X-axis (shown below). 4-3 . The nodes on the surface will get highlighted. and the Plane Information will be listed in the Boundary Condition area. Boundary conditions have to be used on all of the symmetry planes to enforce the correct deformation. 4. Setting Symmetry Boundary Conditions Symmetry is being taken advantage of in this simulation and only 1/16 of the square ring is being modeled. When all three symmetry planes have been added. First select the planes so that the nodes get highlighted and then use the button to add them. the Boundary Condition area should look like the following: 4-4 . Add the boundary conditions for the other two symmetry planes in the same manner.0) which is the normal to the plane. This symmetry plane will now be listed in the BCC list as (1.DEFORM™-3D Labs Click the button to add these boundary conditions.0. Click to exit the INTER-OBJECT window. use the icon to determine a suitable contact tolerance (a value of about 0. Back in the INTER-OBJECT window. click . the following still needs to be done: 1) Highlight the Top Die in the Object Tree and then click the of 1 in/sec in the -Z direction. Inter-Object Relationships The relationship between the Billet and the Top Die needs to be defined. Use the pull-down Define the friction for the relationship by clicking the menu to select the friction suitable for Cold forming (steel dies). Define a speed 4-5 . Click the icon to open the INTER-OBJECT window. Finishing Setup and Running Simulation To finish the problem setup. button. 4.7. When asked whether you want to add the default inter-object relationships.DEFORM™-3D labs 4.002" will be calculated) and then click the button to generate contact. If you rotate the objects around.6. you will see that contact was generated between the two objects. button. select the icon and measure the edge length of a few of the smaller elements in the Billet. This procedure is illustrated below.8. Click to close the SIMULATION CONTROL window. Each time this is done a mirror image of the billet will be displayed. the small 1/16 section has to be mirrored about the symmetry planes. The only should deal with Volume Compensation . Assign this material to the Billet.ignore this for this lab. Clicking the icon opens the SYMMETRY DEFINITION window. 4. Post Processing When the simulation is complete. Use the mouse to click on the symmetry planes on the Billet. in the to return to the MAIN window. Change the Simulation Title to Square Ring. review the results by clicking the button. In reality this part is a full square ring. which is 1/3 of this small edge length. 3) Click the icon to open the SIMULATION CONTROL window. Once the database has been generated. Start the simulation by clicking Monitor the progress of the simulation by looking at the Message file. to define a material for the Billet. 4-6 . Click the button and set the Number of Simulation Steps to 30 and set the Step Increment to Save to 2. so it would be useful to be able to view the entire part in the Post-processor. the DATABASE GENERATION window. Repeat the process until the entire billet is shown.02 in/step.06”. making sure that the option is checked. Save a keyword file for the problem by clicking the button. To determine an appropriate step size. To create the entire object. Click to check the problem. and then use list. Click the icon to open the DATABASE GENERATION window. Select the material 'AISI-1045. Set the Primary Die to Top Die. Generate a database by clicking . An average length of a short edge is around 0. Use a Constant Die Displacement per step of 0. COLD' from the Steel Category.DEFORM™-3D Labs 2) Click the icon in the General page. When finished viewing the results of the simulation.DEFORM™-3D labs Once the complete part is displayed in the DISPLAY window. Play through the steps to observe how the square ring deforms as it is compressed. When you are back in the MAIN window. close the SYMMETRY DEFINITION window. Experiment with viewing the different state variables such as effective strain. window. exit DEFORM-3D by selecting 4-7 . use the icon to return to the MAIN .