DEFORM-3D Software Research Articles

Численный анализ эволюции процесса гофрообразования при косом обжатии пластины в условиях гибки уголковых деталей

The paper considers the problem of corrugation developing on walls of parts during sheet metal forming. We performed a numerical experiment using Deform-3D software to simulate manufacturing operations pertaining to forming a workpiece in the cramped conditions of the die. We established probabilities and conditions for corrugations developing on the shelves of angle metal parts representing a wide range of aircraft components, such as stringers, stiffeners and structural elements of lattice rudders and wings.

Influence of deformation parameters on quality of billets and grinding balls during their production from rejects of rail steels

The conducted studies have determined the regularities of influence of rolling parameters of billets and grinding balls in their production from the rejects of K76F rail steel on probability of defects formation during deformation. Modeling of the rolling process of high-grade billets from the rejects of continuously cast ingots of rail steel of the specified grade in DEFORM-2D software package allowed us to establish a significant effect of such parameters as: partial coefficients of drawing along the transfer bar, frequency of rolling edges, and rolling temperature, on the probability of defect formation, characterized by the maximum value of the Cockcroft-Latham criterion in cross section of the rolls. It is shown that an increase in the coefficients of drawing (compression) along the transfer bar, due to intensification of the rolling mode and an increase in frequency of edging, reduces the likelihood of defects forming during rolling by reducing the temperature inhomogeneity along the rolls section. The established effect of temperature increase on reducing the probability of defects formation is due to an increase in plasticity of the considered rail steel. Based on the data obtained, general recommendations are formulated on the directions of improving the rolling modes of billets from the rejects of rail steels and restrictions on their application in practice. Based on the results of modeling the rolling of grinding balls from the rejects of rail steel on a helical rolling mill, a significant effect of an increase in the deformation temperature on reduction of cracking in the balls axial zone, due to an increase in the steel ductility, was established. Therefore, a new mode of rolling grinding balls from the rejects of K76F rail steel was developed, which provides an increase in impact resistance of grinding balls while maintaining high surface hardness. Effectiveness of this mode is confirmed by the results of its pilot testing in conditions of the ball rolling mill at JSC “Guryevskii Metallurgical Plant”.

EVALUATION OF SURFACE ROUGHNESS IN DRILLING OF AA 7075 T6 PLATE WITH DIFFERENT CUTTING TOOL GEOMETRIES WITH EXPERIMENTAL, STATISTICAL AND DEFORM 3D SIMULATION

The basis of the study is to examine the average surface roughness (Ra) value resulting from drilling AA 7075 T6 plates with drills with different point angles () and under different cutting parameters. However, two different point angles (118° and 135°), three different cutting speeds (Vc) (40, 60 and 80 m/min) and three different feeds (f) (0.04, 0.08 and 0.12 mm/rev) were preferred in the experiments. The effect of cutting and tool geometry parameters on Ra was digitized by performing an ANOVA analysis. It was determined that Ra increased with the increase of Vc,  and f. The parameter with the most significant effect on Ra was Vc with 49.10%, followed by  with 30.52% and f with 13.67%, respectively. In order to examine the reasons for the increase in Ra value more effectively, drilling simulations were carried out under different cutting parameters using Deform 3D software. The simulation estimated temperature, cutting force and damage during drilling. The predicted results and the factors on Ra were revealed. In the experiments carried out with the drill with a tip angle of 135°, it was estimated that the temperature, the temperature, the cutting force and the damage value along the Z-axis were higher than the drill with a tip angle of 118°.

Experimental Study and Finite Element Analysis of Temperature Reduction and Distribution During Machining of Al-Si-Mg Composite Using Deform 3D

Composite materials are promising materials in the manufacturing industry due to the quality of their materials. However, in transforming these materials, the machining process experiences a high-heat generation rate, which has led to the study of temperature distribution, and reduction analysis at the cutting region. High-temperature generation during machining operation leads to thermal deformation on the developed component or parts, affecting the operation life span of the component. Thus, this study investigated the effect of mineral oil-based-Multi-walled carbon nanofluid (MWCNTs) compared to pure mineral oil in the turning of aluminum-silicon magnesium metal composite (AlSiMg) on temperature reduction and distribution. The nanofluid was prepared with 0.4g of MWCNT to 1 liter of mineral oil. The study employed the energy dispersive spectrometer to obtain the chemical composition of the developed nanofluid. Furthermore, Finite element software DEFORM 3D v11.0 uses a lagrangian incremental approach to simulate chip formation and temperature distribution on the workpiece. Also, to study the effects of the machining parameters on the temperature distribution. The experiment results showed a significant reduction of 11.9% in temperature when machining with nanofluid compared to pure mineral oil. The simulation results showed that the temperature increases as the cutting speed and feed rate increase. The minimum temperature via the DEFORM 3D Finite Element Model simulation was achieved at spindle speed 870 rpm, feed rate 2 mm/rev, and depth-of-cut 1 mm. In conclusion, the study recommends that the manufacturing industry employ the optimized machining parameters during the turning of AlSiMg metal matrix composite for a sustainable machining process.

Effects of Preheating Temperature on Deformed AA6061 Aluminium Properties of Hot Equal Channel Angular Pressing (ECAP) by Using Deform-3D Software

Effects of Preheating Temperature on Deformed AA6061 Aluminium Properties of Hot Equal Channel Angular Pressing (ECAP) by Using Deform-3D Software

An extrusion−shear−expanding process for manufacturing AZ31 magnesium alloy tube

A new severe plastic deformation method for manufacturing tubes made of AZ31 magnesium alloy with a large diameter was developed, which is called the TCESE (tube continuous extrusion−shear−expanding) process. The process combines direct extrusion with a two-step shear−expanding process. The influences of expanding ratios, extrusion temperatures on the deformation of finite element meshes, strain evolution and flow velocity of tube blanks during the TCESE process were researched based on numerical simulations by using DEFORM-3D software. Simulation results show that the maximum expanding ratio is 3.0 in the TCESE process. The deformation of finite element meshes of tube blanks is inhomogeneous in the shear−expanding zone, and the equivalent strains increase significantly during the TCESE process of the AZ31 magnesium alloy. A extrusion temperature of 380 °C and expanding ratio of 2.0 were selected as the optimized process parameters from the numerical simulation results. The average grain size of tubes fabricated by the TCESE process is approximately 10 µm. The TCESE process can refine grains of magnesium alloy tubes with the occurrence of dynamic recrystallization. The (0001) basal texture intensities of the magnesium alloy tube blanks decrease due to continuous plastic deformation during the TCESE process. The average hardness of the extruded tubes is approximately HV 75, which is obviously improved.

Investigation on Interfacial Bonding Characteristics of Steel/Aluminum Bi-Metal Gears by Hot Forging Processing

In this study, steel/aluminum bimetal gears were manufactured under different deformation degrees by using hot forging processing. Optical microscope (OM), scanning electron microscopy (SEM) and energy disperse spectroscopy (EDS) were used to observe morphologies and the element composition of the interface region of the bimetal gears with different deformation degrees. Results show that the interface region between steel and aluminum is of mechanical bonding characteristics when the deformation degree is 50% and 70%, and the steel–aluminum interface joining zone is of the metallurgical bonding feature when the deformation degree is 90%. Finite element (FE) simulation of the hot forging process of the bimetal gear was carried out by using DEFORM-3D software. The simulation results show that the increase in the difference between the interfacial radial stress and the flow stress of the steel helps to form metallurgical bonding at the steel–aluminum joining zone.

Numerical Simulation of Fine Blanking Die Wear and Die Performance Analysis

In order to study the die wear law of rotary fine blanking helical cylindrical gear, a three-dimensional rigid plastic finite element model of rotary fine blanking helical cylindrical gear is established on the Deform-3D software platform. Based on the Archard wear model, this paper analyzes the die wear in the fine blanking process, obtains the wear distribution of each point on the working surface of the die, determines the maximum wear area, and makes a comparative analysis with the fine blanking die wear of spur gear. Through the single factor variable method, this paper studies the effects of reverse jacking force, blank holder force, blanking speed, punch and die clearance, die fillet radius, and die initial hardness on die wear. The test results show that when the punch reduction is the same, the wear of the female die of fine blanking helical cylindrical gear is greater than that of fine blanking spur cylindrical gear. When the counter jacking force increases from 100 kN to 200 kN, the maximum wear of the die gradually increases from 6.91 × 10–6 mm to 9.38 × 10–6 mm; when the blank holder force increases to 3/4 of the blanking force, the die wear decreases with the increase of blank holder force; it is ideal when the blanking clearance is 0.5% t (0.02 mm). Conclusion. The wear model can accurately predict the relationship between main process parameters and wear in the process of rotary fine blanking, and the measures to reduce die wear are put forward from the aspect of process design.

Investigations of Formability and Dynamic Recrystallization Development of Titanium Alloys During Dieless Wire Drawing Processes

This study investigates the formability and grain size evolution during the dieless wire drawing process of titanium alloy Ti–6Al–4V. First, thermocompression tests of Ti–6Al–4V billets are conducted to obtain their flow stresses at different temperatures and strain rates. Dynamic recrystallization (DRX)‐related constants and grain size prediction models for titanium alloy Ti–6Al–4V are established from the flow stress curves through regression analyses. Then, a finite element software DEFORM 2D coupled with the established DRX models is adopted for DRX volume fraction and grain size evolution simulations of titanium alloy Ti–6Al–4V during dieless wire drawing processes. The effects of various drawing conditions, such as drawing speed, drawing temperature, and area reduction, on the formability of the wire after the dieless drawing process are discussed. Finally, a dieless drawing machine with a high‐frequency induction heating apparatus and a cooling system is developed. A series of experiments of dieless drawing of titanium alloy Ti–6Al–4V wires at different drawing speeds, drawing temperatures, and cooling rates are conducted. The analytical forming limits of area reductions and grain sizes are compared with experimental values to validate the finite element analysis and DRX models.

Investigation and finite element simulation on the MRR and tool wear of aluminium silicon alloy during turning process

In this study tool wear, cutting zone temperature, cutting forces, and material removal rate (MRR) were analysed using three different coating materials during the turning of high silicon aluminium alloy. The results that are derived on coating thickness were analysed in terms of specific coating materials from the proposed numerical investigation. Feed rate was also analysed with respect to output performance on tool wear, cutting temperature, MRR, and cutting forces. Decrease of 90% wear depth on the work piece was confirmed from titanium carbide coated with 3 microns (μm) coated tool and compared with Al2O3 coated tool during the comparison study between coated tools. Cutting forces were determined with proper care and close observation. The highest tool wear of 0.00461 mm was observed using Al2O3 coated tool thickness of 5 microns (μm). The lowest tool wear of 0.00043 mm was observed using TiC coated tool thickness of 3 microns (μm) with minimum cutting force of 74.31 N and also the highest MRR was obtained in the same. It was evident from the observation that the reduction of forces occurred using 2 microns (μm) coated tool on Al2O3leading to the drastic reduction in the thickness up to 67%. The value again reduced when compared with titanium carbide tool on the work piece metal. The analysis established the minimization of tool wear, cutting force, cutting temperature due to lower feed rates. But there was an increase in case of MRR due to lower feed rates. Al2O3 coated cutting tool insert which has maximum tool wear was chosen for the experiment work and the simulations were carried out using Deform2D software. Tool wear length was compared by using SEM images and tool wear was discussed.

Predictions of stress distribution and material flow in coining process for bi-material commemorative coin

Bi-material commemorative coins have the characteristics of weight reduction, beauty and corrosion resistance. However, due to different characteristics of bi-materials, defects such as stress concentration, drop of inner core and micro-cracks often occur at interface of materials in usage. Engineers usually employ multiple mold trials to check the bonding state of two material regions, judge the stress concentration area and modify the process to avoid micro-crack sprout. Based on the professional metal forming software Deform 3D, stress distribution and material flow in coining processes for single and bi- material commemorative coins are studied. Numerical examples demonstrate that there are three typical stages over the whole process whether the coin is single or bi- material. And stress concentrations appear at the corners of upper/lower dies and the material interface in case of bi-material. The former concentration lead to sprout of micro-cracks along the shear bands and the latter triggers cracks at the interface. In addition, two materials with different hardness are adopted in the core and ring, respectively, to investigate the mutual interaction behavior at interface. Numerical findings indicate that large strains occur at the edge and the interface in case of bi-material with soft core. These imply that deep adhesion happens at the interface in case of that soft material is in the core. It suggests that hard material in the inner core and soft one in the outer ring may cause falling of the core.

Investigation of energy-power parameters of thin sheets rolling to improve energy efficiency

In order to study processes occurring during manufacturing of thin steel sheet by cold rolling and change of energy-power parameters, simulation was performed using engineering software DEFORM 3D, which allows to reflect rolling technology accurately. Model of treatment process was created, output data, modes and temperature of treatment, motion parameters of rolls and sheets were set, material of workpiece was selected and its properties were determined. During simulation of sheets cold rolling process, Lagrange analysis was used, number of simulation steps was 100. Process of plastic deformation of metal along curved grid was investigated, vector displacement field was determined, and it was found that maximum movement of metal occurs under effect of top roll. Distribution of stress-strain state was investigated and maximum stress in strain zone was determined. Distribution of rolling forces and torque was investigated, which allowed to determine their maximum values. Maximum rolling forces and torque were observed at 7 – 9 th second of treatment, and in future they were reduced due to the fact that pushing force disappeared and steady process began.

Development of a finite element model for calculation of the thermal field of coil rolled products in the thermomechanical process

A finite element model has been developed in the Deform-3D software package for calculating the thermal field of low-alloy steel coil rolled products during rolling in the finishing group of stands and cooling on the discharge roller table of the 2000 wide-strip hot rolling mill of PJSC Magnitogorsk Iron and Steel Works (PJSC MMK). The proposed model takes into account heat release during plastic deformation, cooling of the strip due to metal contact with air, heat transfer to the work rolls, cooling of the strip by water supplied in the process of interstand cooling and in the accelerated cooling unit on the discharge roller table. At the same time, the features of cooling by both upper and lower collectors are taken into account. To achieve the required coiling temperature, the possibility of differentiated activation of collectors of the upper and lower sections of the accelerated cooling unit was implemented, which was introduced into the finite element model. Cooling by water jets was updated by dividing the contact of the cooled strip with water into two zones - the area of water impact with the sheet surface and the area of film boiling. As a result of the analysis of the thermal state of the sheet, an assessment was made of the nature of its change depending on the characteristics of each stage of thermomechanical treatment (TMT). The use of the presented model in the development of TMT technological modes makes it possible to evaluate their correctness, as well as to provide the possibility of predicting the structure and properties formed over the thickness of rolled steel in the process of controlled rolling with accelerated cooling.P. P. Poletskov, S. V. Denisov, P. A. Stekanov, E. V. Braichev, and P. G. Adishchev, post-graduate student of the MTa-21-2 group, took part in the work.The work was carried out at the Nosov Magnitogorsk State Technical University with the financial support of the Ministry of Education and Science of Russia as part of the implementation of a comprehensive project to create high-tech production (Agreement with the Ministry of Education and Science of Russia No. 075-11-2021-063 dated 06/25/2021).

Effect of volcano-like textured coated tools on machining of Ti6Al4V: an experimental and simulative investigation

The present study was to reduce the adhesion and wear that happened on the rake face during machining of Ti6Al4V alloys by employing volcano-like textured coated tools. A combination of experimental and simulative investigation was adopted. DEFORM-3D software with updated Lagrangian formulation was used for numerical simulation, and the thermo-mechanical analysis was performed using Johnson–Cook material model to predict the cutting forces, cutting temperature, chip morphology, and tool wear. In cutting experiments, volcano-like textures with different area densities (10%, 20%, 30%) were fabricated by fiber laser on the rake face of cemented carbide tools close to the main cutting edge. Then, these textured tools were deposited with CrAlN coating through cathodic vacuum arc ion plating technique. Experiments in cutting Ti6Al4V alloys were carried out with the textured coated tools and non-textured coated tool under dry and wet cutting conditions. Then, cutting forces, chip morphology, and tool wear were investigated. The results showed that textured coated tools were superior to the conventional tool. Especially in wet cutting, the main cutting force and radial force of the coated tool with texture area density of 20% (VCT2) were reduced by 11.6% and 21.25%, respectively. Surface morphology of VCT2 tool had lower workpiece adhesion on the rake face. Therefore, VCT2 tool showed a better cutting performance. Finally, the mechanisms of textured coated tools under wet cutting conditions were proposed.

Multi-directional forging of large-scale Mg-9Gd-3Y-2Zn-0.5Zr alloy guided by 3D processing maps and finite element analysis

The three-dimensional (3D) processing maps of cast Mg-9.0Gd-3.0Y-2.0Zn-0.5Zr alloy were established based on isothermal compression tests and dynamic material model (DMM). The stable and power-efficient forming domains were determined by considering both the instability and power dissipation efficiency maps. Multi-directional forging (MDF) was then simulated by employing finite element (FE) analysis in the Deform-3D software, using the 3D power dissipation efficiency maps as input. The optimal forging parameters were thus obtained for a large-scale ingot with 430 mm in diameter and 440 mm in height, i.e., a forging temperature of 450 °C and forging speed of 10 mm/s. Finally, a Mg-9.0Gd-3.0Y-2.0Zn-0.5Zr cake-shaped forged part with 900 mm in diameter and 100 mm in height was produced. After T6-heat treatment, the edge and center of the forged part exhibit homogeneous microstructure and relatively consistent properties, with the tensile strength, yield strength, and elongation being about 400 MPa, 320 MPa, and 14.0%, respectively. Using transmission electron microscopy, the main strengthening phases were revealed to be the dense nano-scale β′ phases that are uniformly distributed inside the material.

Design and Finite Element Analysis of a New Kirschner Wire for Fixing Bone Fractures in Orthopedic Surgery

In this study, a new Kirschner wire (K-wire) design was performed to fix bone fractures in orthopedic surgery. The numerical analyses were completed based on the finite element method (FEM), using Deform-3D software. In this kind of numerical analyses using the FEM, friction, material model, the load and boundary conditions must be defined correctly. It has been seen that the new design is more advantageous in terms of implant failure or stability of fracture fixation. In addition, a good compatibility was found between the experimental results and the finite element analysis (FEA) results. This confirmed the accuracy of the finite element model. Therefore, this finite element model can be used reliably in drilling processes. We believe that with the use of new design investigated may have the role on the patients taking away from recurrent anesthesia and orthopaedic surgical risk.

Estimating Machinability Factors in Turning of Inconel 625 under different lubricating conditions using 3D DEFORM FE Analysis

This paper contributes to the investigation of machinability factors in turning the nickel- based Inconel 625 superalloy with PVD coated TiAlN tungsten carbide cutting insert. The machinability parameters – cutting force (Fc), tool wear rate (𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑⁄), and tool temperature (T) are visualized graphically using the FE model based Deform 3D software interface. The paper discusses the application of boundary conditions, and meshing used for simulating results. The results of the dry turning simulation showed a maximum level of cutting force, tool-tip temperature, and tool wear rate in comparison with conventional MQL and NMQL conditions. The NMQL conditions showed a reduction in cutting force with the use of h-BN NMQL environment compared with dry and conventional MQL machining by 41% and 27%, respectively. Further, the comparison of cutting tool temperature for three simulated conditions showed a clear-cut reduction of temperature in NMQL conditions in comparison with dry and conventional MQL, by 44% and 30%, respectively.

Optimization of tool geometric parameters for a small fluteless forming tap (FFT)

The small blind internal thread (SBIT) plays a very important role to firmly fastening some functional components on the cover of 3C electronic products. The small internal thread was made in a blind hole using a fluteless forming tap (FFT) without producing chips. However, the four geometric parameters of the FFT (tool width (W), tooth root diameter (D2), front-end diameter (Df), and tooth angle (θ)) will affect the thread filling rate (f) and minimum torque (T) in tapping process. This study reports the Box-Behnken design (BBD), combined with DEFORM-3D (finite element model) and MINITAB (regression analysis) software, to tap 7075-T6 aluminum alloy with small FFT to obtain reliable results of thread filling rate and minimum torque. The experimental results show that the BBD can accurately predict and simulate the thread filling rate of tapping 7075-T6 aluminum alloy. The modeling software and experimental design used in this research are very suitable for the optimal design of the FFT used in industrial production.

Simulation Research on Die Forging Process Optimization of the FDN Type Anti-vibration Hammer Head in UHV Transmission Lines

Traditional anti-vibration hammer heads are mainly manufactured by gravity casting technology, which has many internal defects and limited mechanical properties, which cannot meet the technical requirements for higher-strength anti-vibration hammers in the construction of UHV transmission lines. Die forging is an advanced material forming process for producing low defect and high strength anti-vibration hammer. However, the process parameters should be strictly controlled to realize the complete filling of forgings and reduce the damage of forgings and dies.In this paper, the die forging process of the FDN type anti-vibration hammer head was simulated by using Deform-3D software platform, and the optimal forging process parameters were proposed as follows: the diameter of the blank is 65mm, the length of the blank is 184mm, the pressing speed of the upper die is 200mm/s, and the preheating temperature range of the blank is 800?∼1000?. The mechanical properties of the anti-vibration hammer after process optimization met the requirements of the corresponding strength grade products.

A novel process for manufacturing large-diameter thin-walled metal ring: Double-roll pendulum hot rotary forging technology

Large-scale thin-walled metal ring parts are the key main structural parts in new energy sources and aerospace equipment. How to form reliable large-diameter thin-walled metal rings has become the focus of attention of researchers. This paper proposes a double-roll pendulum hot rotary forging (DRPHRF) process for forming such components and demonstrates the feasibility of forming rings with a diameter of 4 m and a thickness of 0.1 m (axial) using this process. The forming process of DRPHRF is analyzed and designed, and the critical instability and forming conditions are obtained. The finite element model of the ring DRPHRF was established in the DEFORM-3D software using the scale-down process with a ratio of 10:1, and the accuracy of the model was verified through experiments. Based on the reliable finite element model, the deformation behavior of the ring DRPHRF is analyzed. The results show that each part of the ring is subjected to periodic stress, which reduces the residual stress. The uniform circumferential equivalent plastic strain (PEEQ) distribution and the characteristics that the axial PEEQ becomes uniform as the thickness decreases are conducive to forming a thin-walled ring with uniform performance. There is less heat loss during the forming process, which is beneficial to reduce the stress during forming.