DEFORM-3D Software Package Research Articles

Computer simulation and research of the hot rolling process in DEFORM-3D

Abstract The work presents the results of hot rolling process modeling using three-dimensional numerical modeling based on the DEFORM-3D software package, which is based on the finite element method (FEM). In the process of modeling, the work rolls were considered as absolutely rigid bodies. The number and type of elements were determined on the basis of the geometric features of the workpiece and the accuracy of the calculation. The adequacy of the calculations was determined by comparison with experimental data, semilunar on the current production. Discrepancies left no more than 5%. That allows us to consider the model adequate.

Comparison of stress-strain behavior during helical rolling process with various deformation regimes obtained by mathematical simulation in DEFORM-3D software package

In this study, mathematical models of helical rolling under various deformation regimes were built using the Deform-3D software package. Stress-strain behavior after all studied regimes were compared in dependence with technological rolling parameters and geometrical characteristics of helical rolls. Obtained results defined that helical rolling provides appearance of macroshear deformation in transverse and longwise direction of workpiece and high value of strain intensity defines both during rolling in helical rolls and subsequent flattening. Appearance of multidirectional macroshear deformation seems to provide the increase of technological plasticity, additional melting of cast macrostructure, reduction of transverse anisotropy and decrease the energy-power parameters of longitudinal rolling.

Выбор геометрических параметров инструмента для малоотходной безуклонной горячей объёмной штамповки воротниковых фланцев методом “раздача-выдавливание”

In the course of computer modeling based on the DEFORM 3D software package, an experiment was conducted to determine the optimal parameters of the tool for the distribution-extrusion process. The simulation was performed by varying the cone angle of the knife, as well as by changing the conditions of contact friction. The satisfactory geometrical parameters of the knife cone, namely, the deflection angle (10 0 ) and the coefficient of friction (0.25), are determined. The simulation was carried out on the model of forging the collar flange 50-16-11-1-B. The definition of the above parameters will optimize the process of forming, eliminating the calibration operation

Forging property, processing map, and mesoscale microstructural evolution modeling of a Ti-17 alloy with a lamellar (α+β) starting microstructure

This work identifies microstructural conversion mechanisms during hot deformation (at temperatures ranging from 750 °C to 1050 °C and strain rates ranging from 10−3 s−1 to 1 s−1) of a Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17) alloy with a lamellar starting microstructure and establishes constitutive formulae for predicting the microstructural evolution using finite-element analysis. In the α phase, lamellae kinking is the dominant mode in the higher strain rate region and dynamic globularization frequently occurs at higher temperatures. In the β phase, continuous dynamic recrystallization is the dominant mode below the transition temperature, Tβ (880~890 °C). Dynamic recovery tends to be more active at conditions of lower strain rates and higher temperatures. At temperatures above Tβ, continuous dynamic recrystallization of the β phase frequently occurs, especially in the lower strain rate region. A set of constitutive equations modeling the microstructural evolution and processing map characteristic are established by optimizing the experimental data and were later implemented in the DEFORM-3D software package. There is a satisfactory agreement between the experimental and simulated results, indicating that the established series of constitutive models can be used to reliably predict the properties of a Ti-17 alloy after forging in the (α+β) region.

Influence of extrusion speed on the seam weld quality in the porthole die extrusion of AZ31 magnesium alloy tube

In the present work, an accurate 3D-FE model for simulating the extrusion process of AZ31 magnesium alloy tube was established based on the DEFORM 3D software package. The metal flow behavior and formation process of weld seam in the porthole die were revealed. The evolutions of temperature, velocity, and effective stress during the whole extrusion cycle were investigated. The K welding criteria was utilized to evaluate the influence of extrusion speed on the seam weld quality. Extrusion experiments were carried out at the extrusion speed ranging from 0.25 to 4 mm/s on an 800-t extrusion press. The simulation results show that the temperature distribution in the workpiece was not homogeneous. As the extrusion process proceeded, the greater the temperature gradient of workpiece was. The maximum temperature appeared at the bearing region. The dead metal zones existed at the corner between the container and the die face and between the bottom and the sidewall of welding chamber. The effective stress near the bearing and welding chamber was maximum, followed by the inlet ports of porthole die, and the minimum value was located in the container. As extrusion speed increased, the temperature, welding pressure, and effective stress on the welding plane increased simultaneously. The calculated K value decreased rapidly when extrusion speed increased from 0.5 to 2 mm/s and then reduced slowly when larger than 2 mm/s. Extrusion speed had a negative influence on the seam weld quality. The criteria exhibited a good predicting capability as compared with the experimental results. The optimum extrusion speed was about 0.5 mm/s for the extrusion of AZ31 magnesium alloy tube at the billet temperature of 400 °C on the 800-t extrusion press.

Mesoscale modeling of dynamic recrystallization behavior, grain size evolution, dislocation density, processing map characteristic, and room temperature strength of Ti-6Al-4V alloy forged in the (α+β) region

Abstract This work focuses on a series of microstructural predictions regarding the dynamic recrystallization (DRX) behavior, change in grain size and dislocation density. Additionally, this study includes the prediction of the room-temperature-strength and the processing map characterization of Ti-6Al-4V alloy after forging in the (α+β) region. The experimental tests of the forgings reveal that the mechanism of microstructural conversion depends on the testing conditions. That is, superplastic behavior is exhibited at lower strain rates and higher temperatures. With an increasing strain rate and decreasing temperature, DRX occurs in a continuous manner. A set of constitutive equations that model the microstructural evolution, processing map characteristics and room temperature strengths is established by optimization of experimental data, followed by implementation into the DEFORM-3D software package. There is satisfactory agreement between the experimental and simulated results. Thus, a series of constitutive models (established in this work) is found to enable the reliable prediction of properties of Ti-6Al-4V alloy after forging in the (α+β) region.

The simulation of the workpiece and saw teeth heating during the high-speed cutting process

The paper presents the result of the simulation of the workpiece and saw teeth heating during high-speed cutting using the Deform 3D software package. The distribution of temperature and stressing fields during the high-speed cutting process was obtained. The investigation was confirmed by metallographic analysis, and it shows good convergence of simulation results with practical results for the temperature fields.

Finite-element simulation of flanging in the deform 3D software package

The results of a finite element simulation of the rolling of cylindrical workpieces using the DEFORM 3D software package are presented. The curve of the limiting plasticity of L63 brass that corresponds to various schemes of the state of stress in a workpiece is plotted. The deformation paths of the characteristic regions in a rolled part are calculated.

Development of nondestructive warm rolling schedules for nanocrystalline beryllium using mathematical simulation

The critical values of the Cockcroft-Latham and Ayada criteria, which are embedded in the Deform-3D software package and can be used to describe the fracture of nanocrystalline beryllium at various stages of warm rolling, are determined. It is shown that excess over these critical values leads to the fracture of beryllium during both simulation and experimental rolling. Nondestructive conditions are developed for multipass warm rolling of beryllium with the minimum number of long-term intermediate high-temperature annealing.

Extrusion load prediction of gear-like profile for different die geometries using ANN and FEM with experimental verification

This paper deals with the extrusion of gear-like profiles and uses of finite element method (FEM) and artificial neural network (ANN) to predict the extrusion load. In the study, gear-like components has been manufactured by forward extrusion for the AA1070 aluminum alloy and the process was simulated by using a DEFORM-3D software package to establish a database in order to provide the data for ANN modeling. Serious experiments were performed for only one die set and four teeth gear profile to obtain data for comparing with DEFORM-3D results. After verifying a highly appropriate FEM simulation with the experiment at the same conditions, Results were enhanced for different die lengths, extrusion ratios, and two extra teeth number as three and six using FEM simulations. Subsequently, the data from the performed FEM simulations were submitted for the best obtained ANN model. Finally, a good agreement between FE-simulated and ANN-predicted results was obtained. The proposed ANN model is found to be useful in predicting the forming load of the different die set variations based on the reliable test data.

Prediction of energy consumption and environmental implications for turning operation using finite element analysis

This article is concerned with the experimental and numerical investigation of energy consumption involved in the turning of Ti6Al4V titanium alloys. Energy consumption of a machining process is considered as an important machining performance indicator. This article aims to propose an approach for the prediction of energy consumption and related environmental implications using finite element modeling simulations. Machining experiments were conducted using uncoated carbide tools under dry cutting environment. DEFORM-3D software package was utilized to simulate finite element–based machining simulations. Experimental validation was mainly conducted by focusing on the cutting forces and power consumption measurements. Simulated results of the cutting force and power consumption were found in a good agreement with the experimental findings. The amount of CO2 emission resulting from energy consumption during the machining phase is highly dependent on the geographical location. This study also incorporated the energy mix of United Arab Emirates for the environmental calculations. Finally, in the light of proposed methodology, possible future directions and recommendations have also been presented.

Numerical Simulation of Microstructure Evolution in AZ31 Magnesium Alloy during Equal Channel Angular Pressing

The microstructure and material properties of AZ31 magnesium alloy are very sensitive to process parameters, which directly determine the service properties. To explore and understand the deformation behavior and the optimization of the deformation process, the microstructure evolution during equal channel angular pressing was predicted by using the DEFORM-3D software package at different temperature. To verify the finite element simulation results, the microstructure across the transverse direction of the billet was measured. The results show that the effects strain and deformation temperatures on the microstructure evolution of AZ31 magnesium during ECAP process are significant, and a good agreement between the predicted and experimental results was obtained, which confirmed that the derived dynamic recrystallization mathematical models can be successfully incorporated into the finite element model to predict the microstructure evolution of ECAP process for AZ31 magnesium.

Modeling of plastic torsion of a long-length cylindrical billet

As a result of the computer modeling performed with the use of a DEFORM 3D software package, the effect of a method for torsion and deformation time on the deformation nonuniformity during the torsion of a cylindrical billet of Pb-40% Bi alloy is determined.

Study of rolling in helical rolls by mathematical simulation with the DEFORM 3D software package

A mathematical model is developed and adapted for lengthwise rolling in special-profile helical rolls using the Deform 3D software package. The metal flow in rolling in helical rolls is studied. The state of stress in the deformation zone is analyzed, and the rolling force is calculated as a function of the technological rolling parameters and the geometrical characteristics of the helical rolls.

Case studies on virtual extrusion of aluminium alloys in real size

Two case studies were conducted to illustrate the capabilities of the state-of-the-art computer simulation technology applied to the aluminium extrusion process and demonstrate the usefulness of virtual extrusion in real size to the die designer and extrusion process engineer alike. A deform 3D software package was used for virtual extrusion in real size to manufacture a hollow profile through a porthole die (case I) and two precision solid profiles through a two-hole multi-step pocket die (case II). Temperature, stress and velocity distributions were revealed. In case I, the filling of the ports, welding in the welding chamber and forming of the hollow profile were visualised. The quality of the longitudinal welds along the hollow profile length was assessed. In case II, the deflection of two solid profiles from the centreline to different extents was predicted, thereby providing the guidelines for die design modification. The modified die indeed performed better.

A numerical model based on internal-state-variable method for the microstructure evolution during hot-working process of TA15 titanium alloy

The microstructure and dynamic material properties of Ti–6Al–2Zr–1Mo–1V (TA15) titanium alloy are very sensitive to process parameters, which directly determine the service properties. To explore and understand the deformation behavior and the optimization of the deformation process, a microstructure-evolution model is needed not only to phenomenologically describe the hot deformation process, but also to reflect the interaction between deformation and microstructure evolution and to reveal the deformation mechanism. In this article, we present an experimental investigation of the microstructure-evolution law and the softening mechanism of TA15 deformation in the two-phase region. By using the internal-state-variable method, a set of mechanically based equations that model the evolution of the dislocation density, the recrystallization and the grain size are developed for the TA15 alloy. By integrating the microstructure-evolution model into the DEFORM-3D software package, we predict microstructure evolution during an isothermal, compressive-deformation process, and the model is verified by comparing the experimental results with the calculation. Using the model a simulation and grain-size prediction of the TA15 large-component isothermal forming are carried out, and the results are confirmed experimentally.

Prediction of the Extrusion Load and Exit Temperature Using Artificial Neural Networks Based on FEM Simulation

In the present study, the extrusion process for the AZ31B magnesium alloy was simulated using a DEFORM-3D software package to establish a database in order to provide input data for artificial neural networks (ANN). The network model was trained by taking extrusion ratio, ram speed, shape complexity and ram displacement as the input variables and the extrusion load and exit temperature as the output parameters. The data from FEM simulations were submitted for ANN as a training file and then ANN built were used to predict the target parameters. The ANN predicted results were found to be in agreement with the FEM simulated and experimental measured ones.

Numerical simulation on forging process of TC4 alloy mounting parts

In order to eliminate forging defects appearing in production, based on the rigid-viscoplastic FEM principle, the DEFORM3D software package was employed to simulate the forming process of TC4 alloy mounting part and to optimize the process parameters. In this simulation, the temperature dependency of the thermal and mechanical properties of material was considered. Based on the simulation, the metal flow and thermomechanical field variables such as stress and damage are obtained. The simulation results show that the forging defects are caused by improper die dimension and the optimized die dimension was proposed. To verify the validity of simulation results, forging experiments were also carried out in a forging plant. The forging experiments show that the optimized die dimension can ensure the quality of forging part, and it can provide reference to improve and optimize die design process.