DEFORM-3D Software Research Articles

Analytical model of work hardening and simulation of the distribution of hardening in micro-milled nickel-based superalloy

During the process of micro-milling nickel-based superalloy, the cutting surface is strengthened along with the high strain and strain rate, which leads to work hardening and affects the quality of parts and the tool’s life. At present, there are few analytical models that can predict the micro-hardness of the micro-milled surface. Therefore, the authors focus on the research of the micro-milling work hardening of nickel-based superalloy. Firstly, based on the stress-strain relationship and strain-hardening characteristics of Inconel718, the relationship between hardness and strain of Inconel718 is obtained. Then, based on the established micro-milling force model, the stress of a point in the process of micro-milling is derived. Finally, the surface hardness value of the machined surface is predicted by combining the relationship between the stress-strain and the hardness of the workpiece. In addition, a 3D simulation model of micro-milling nickel-based superalloy groove is established by Deform-3D software to research the distribution of micro-hardness of the machined surface. The research offers reference for improving the surface integrity and fatigue performance of micro-milling nickel-based superalloy and explores a feasible way for revealing the mechanism of micro-milling hardening.

Investigation of FEM Simulation of Machining of Titanium Alloy Using Microgroove Cutting Insert

In this paper, FEM simulation of machining of titanium alloy using microgroove cutting insert has been carried out using DEFORM-3D software. The cutting insert with microgroove has been made with Solidworks software. The 3D machining simulations of all the different types of microgroove patterns in cutting inserts were done at constant cutting variable, i.e. cutting speed of 125.6 m/min, feed of 0.23 mm/rev and depth of cut of 2 mm respectively. The simulation results were partially validated with experiments. There was good agreement between experiment and simulation. The cutting temperature, effective stress, tool wear rate and temperature at the chip/tool interface has been determined. There was an improvement in the machinability criteria using cutting tool with microgroove pattern.

Finite Element Simulation of Rotating Compression Forming

In this study, finite element analyses of Rotating Compression Forming (RCF) of magnesium alloy AZ31 with 20mm in diameter are carried out. A commercial software DEFORM-3D is used to simulate the plastic deformation behavior of magnesium alloy during rotating compression forming processes. Various forming parameters, such as the compression pressures (55, 60, 62 MPa), rotation speeds (10, 20, 30 rpm), rotation numbers (10, 20, 30 revolutions) and forming temperatures (280°C, 320°C, 360°C), are used in the FE simulation to obtain different effective strain distributions. Observation of the gradient microstructure and hardness measurement in the specimens of Magnesium alloy are carried out. From the comparisons of effective strain distributions and the obtained grain size distributions. It is known that a larger effective strain corresponds to a smaller grain size and the maximum effective strain is occurred at the middle of the contact plane of the specimen. Larger effective strain gradients generated with compression pressure of 62 MPa and rotation number of 30 revolutions at the radius of 4 mm.

EFFECTS OF GUIDING CHAMBER ON WELDING PRESSURE IN HOLLOW EXTRUSION DIE DESIGN OF AA7075

Porthole die extrusion has a great advantage in the forming of hollow section of aluminum alloy tube. This paper aims at the development of an extruding seam square tube of AA7075 high strength aluminum alloy. In order to increase the welding pressure of the hollow AA7075 tube in extrusion process, a special die feature has been created. Several different proportions of chamber structure in outlet of extrusion die have been designed. The finite element analysis software DEFORM 3D to analyze various design parameters on the load – displacement and the welding pressure have been studied. In this study, a different high proportion in material guiding chamber has been defined. The results showed that if a suitable material guiding chamber has been built then welding pressure can be increased rapidly. When the ratio of chamber height and length is 2:1 the increased welding pressure is the best.

Simulation studies on Tube End Expansion of AA2014 Alloy Tubes

End forming is defined as forming the end of tubular forms either by inverting the tube or by expanding it. It finds application in many fields such as in automotive and aerospace sectors as power transmission elements, fuel lines, exhaust pipes etc. The main aim of the present work is to expand the AA2014 alloy tubes with different die sets without any fracture. Deform 2D software was used for performing simulations on expanding the tubes with different die set (punch) values having differed forming angles (α = 15°, 30° and 45°) and expansion ratios (rp/r0 = 1.39, 1.53 and 1.67). Experiments were also conducted and the results correlate with the simulation results. The results shows that for the punch having less cone angle (α) values the linear displacement is more rather than higher cone angles. But in the case of higher cone angles the radial displacement is more than the linear displacement.

Servo Forging Technology and Mold Development of the Pulley of AISI-1010 Low Carbon Steel

Aimed at AISI-1010 low carbon steel pulley components, a finite element method-based metal forming simulation software of DEFORM 3D was used to simulate and analyze the near net forging process for the low carbon steel pulley, and to design forging molds. This technology was used in the pulley tooth forging in conjunction with the servo press-based servo motion curve technology. First, the cold forging process of the pulley preform forging and the near net forging were simulated. Also, the applications of the pulse wave servo motion curve in the pulley tooth forging was simulated, which was compared with the traditional motion curve-based forging forming, where the comparisons focused on the maximum forming force and maximum equivalent stress. The results indicated that the maximum forming force and the maximum equivalent stress of the punch caused by the pulse wave servo motion curve was smaller than caused by the traditional motion curve.

Comparison of Different Extrapolation Models for Materials in the Closed-Extruding Fine Blanking Simulation

The selection of the flow stress model of materials has a great influence on the plastic forming simulation of metal. For closed extrusion fine blanking, selecting the accurate and appropriate material flow stress model can make the finite element simulation closer to the real situation, and the simulation data is more reliable. In order to solve the accuracy problem of finite element simulation closed-extruding fine blanking, 5 types of flow stress fitting curve equations were obtained based on the data of sheet metal tensile test. With the secondary development of finite element software Deform-2D, the circular piece of closed-extruding fine blanking forming process was simulated, whose diameter is 14 mm and thickness is 30 mm. The simulation results of different rheological models were compared after physical experiment being carried out.The results show that Ludwik extrapolation rheological model is suitable for finite element simulation of closed-extruding fine blanking technology, which effectively improves closed-extruding fine blanking simulation accuracy. Lay the foundation for the application of closed-extrusion fine blanking in industry.

Simulation and Analysis of One-time Forming Process of Automobile Steering Ball Head

Aiming at the problems such as large machining allowance, low production efficiency and material waste during die forging of ball pin, the cold extrusion process of ball head was studied and the analog simulation of the forming process was carried out by using the finite element analysis software DEFORM-3D. Through the analysis of the equivalent stress strain, velocity vector field and load-displacement curve, the flow regularity of the metal during the cold extrusion process of ball pin was clarified, and possible defects during the molding were predicted. The results showed that this process could solve the forming problem of ball pin and provide theoretical basis for actual production of enterprises.

Densification Optimized Design for CuZnAl Sintered Powders by Different Twist Angle During Twist Extrusion Process by Numerical Method

As a new type of severe plastic deformation method (SPD), deformation of twist extrusion (TE) is mainly determined by the twist angle α and the helix angle β. And when the length of the spiral channel is constant, the twist angle α is indirectly decided to the helix angle β. The numerical simulation model of CuZnAl powder material was established by the finite element software Deform-3D and the influence of the different twist angle α on its densification behavior was simulated in the paper. The results show that spiral channel in TE die structure is a strong shear plastic deformation area and can produce high hydrostatic pressure, and then promotes material density of the powder porous materials. Moreover, the larger twist angle is favorable for densification of the sintered powder material but the densification of the material is not exactly proportional to the twist angleα, and it is the optimized design for TE die because of the minimal uniformity coefficient and the best relative density distribution for the twist angle 270°, too.

Software implementation of a new analytical methodology applied to the multi-stage wire drawing process: the case study of the copper wire manufacturing line optimization

This paper presents the PullWorks software, an expert system that has been developed for the fast and simple design with the aim of optimizing the multi-stage copper wire drawing process. This software has been implemented applying the analytical method and complemented with the results of a series of experimental tests for the correct characterization of the processed material. The expert software system created has been used to model a real drawing line (Cunext Copper Industries S.L., Cordoba, Spain), with a production capacity of more than 30,000 t/year and an installed capacity of 1700 kW. PullWorks has made it possible to propose two modifications in the industrial process reducing its energy consumption by at least 1260 MWh/year: thanks to a reduction in the number of stages in the process lines (from 8 to 5, in the roughing line; from 19 to 13 in finishing) and by the elimination of the annealing treatment between them. The validity of these results has been verified through of the corresponding simulations made by the software Deform2D by means of which the numerical method of the finite elements analysis has been applied, and the solution was partially checked in the industrial process in operation.

Numerical investigation of hot ultrasonic assisted turning of aviation alloys

Aviation alloys exhibit superior properties such as high-strength-to-weight ratio and corrosion resistance but these alloys possess poor machinability. To overcome this disadvantage, new machining methods (Ultrasonic assisted machining, hot machining, etc.) are developed. Hot ultrasonic assisted turning (HUAT) is a new hybrid machining method which changes the cutting system between tool and workpiece, therefore, reduced cutting forces and better surface finish for workpiece are obtained. In this study, 2D finite element (FE) analysis is carried out to investigate the effects of these machining methods on titanium and Hastelloy-X alloys in terms of cutting forces, cutting tool temperatures and effective stresses. DEFORM-2D software is used during analyses. In addition, an experimental study is conducted to verify numerical results. During verification, cutting tool temperature is taken into consideration. It is confirmed that HUAT technique reduces cutting forces and effective stress significantly but cutting temperature increases compared to conventional and ultrasonic assisted turning.

Analysis of multipoint cutting tool temperature using FEM and CFD

Nimonic C-263 is a British nickel–chromium–cobalt–molybdenum alloy specially meant to be used in high-temperature and high-strength applications. Consequently, it produces high thermo-mechanical loads on the machining tool when machined. As a result, excessive heat is generated during dry drilling, between Nimonic C-263 and tungsten carbide tool coated with Alcorna, which in turn reduces the durability of the tool. In order to determine the temperature distribution of the tool, the coupling of finite element machining simulations along with computational fluid dynamics simulations is performed. The temperature distribution of the tool under dry condition is simulated via the DEFORM 3D software and the Altair AcuSolve software. Further investigation under cooling condition is performed using Altair AcuSolve software. The mass flow rate of the coolants is kept constant when the temperature distribution is obtained during the CFD analysis under cooling condition. Silver nano coolant has high heat reduction compared to other coolants and is found to generate 34% less heat than dry condition.

Selection of Optimal Hot Extrusion Process Parameters for AA6061-Fly Ash Composites

The simulation of hot extrusion process is a challenging problem in process modeling because of very large deformations, strain rates and temperature changes during the process. The process development in industrial extrusion is to a maximum extent based on trial and error and often involves full size experiments. Numerical simulations can replace most of these experiments, which are often both time consuming and expensive. Hence in the present work, attempt has been made to simulate hot extrusion process. AA6061-flyash Metal Matrix Composite(MMC) as billet, H13 tool steel as the die, 400oC as billet temperature and extrusion ratio of 25:4 are used as simulation parameters. Simulation is performed using software DEFORM 3D by varying ram speed, Cone Half Angle (CHA) and friction coefficient with extrusion load. The effects of change of process parameters were observed and optimal process parameters were selected.

Effect of Brasssheathing on ECAP of Ti-6Al-4V Alloy by Deform-3D Simulation and Experimentalanalysis

The Deform-3D software was used to simulate and analyze the equal channel angular pressing (ECAP) of Ti-6Al-4V alloy with and without brass sheathing. The results show that the Ti-6Al-4V alloy samples with and without brass sheathing is both maintain a regular shape after ECAP. The effective strain of points on the cross section of sample with brass sheathing is smaller than that of sample without brass sheathing, but the extrusion load of sample with brass sheathing is smaller, and the difficulty of Ti-6Al-4V alloyin ECAP process was reduced. The experimental result also proves the feasibility of ECAP of Ti-6Al-4V alloy with brass sheathing, and the change of microstructure is accord with the deformation characteristic of ECAP.

Performance improvement studies for cutting tools with perforated surface in turning of titanium alloy

In turning process, the cutting tool is essential for shaping materials. The cutting tools with various perforated surfaces help to increase the cutting tool life. Also, advances in CNC machining technologies have enhanced the productivity of machining process. One of the best or futuristic approaches in modern manufacturing engineering is the use of FEM Simulation for the metal cutting process. FEM simulation helps in understanding the metal deformation process and also helps in the reduction of experiments. The simulation helps the researchers to predict the major influencing cutting variable values without carrying out any experiment which is time-consuming and expensive. This research presents the simulation study of the performance of micro-hole patterned Polycrystalline Diamond cutting insert in machining Titanium alloy (Ti-6Al-4V). Micro-holes are drilled using Electrical Discharge Wire Drilling machine on the rake face of Polycrystalline Diamond (PCD) cutting inserts. FEM analysis is carried out to evaluate the effect of perforations on the mechanical integrity of insert. The micro-hole patterned insert is modeled in PRO-E modeler and simulated using DEFORM-3D software. The effective stress, strain, and temperature distribution are analyzed and the results are compared with the normal insert.

Performance improvement studies for cutting tools with perforated surface in turning of titanium alloy

In turning process, the cutting tool is essential for shaping materials. The cutting tools with various perforated surfaces help to increase the cutting tool life. Also, advances in CNC machining technologies have enhanced the productivity of machining process. One of the best or futuristic approaches in modern manufacturing engineering is the use of FEM Simulation for the metal cutting process. FEM simulation helps in understanding the metal deformation process and also helps in the reduction of experiments. The simulation helps the researchers to predict the major influencing cutting variable values without carrying out any experiment which is time-consuming and expensive. This research presents the simulation study of the performance of micro-hole patterned Polycrystalline Diamond cutting insert in machining Titanium alloy (Ti-6Al-4V). Micro-holes are drilled using Electrical Discharge Wire Drilling machine on the rake face of Polycrystalline Diamond (PCD) cutting inserts. FEM analysis is carried out to evaluate the effect of perforations on the mechanical integrity of insert. The micro-hole patterned insert is modeled in PRO-E modeler and simulated using DEFORM-3D software. The effective stress, strain, and temperature distribution are analyzed and the results are compared with the normal insert.

Analysis of Dynamic Effects during Rotary Forging of Cylindrical Sintered Preforms

The present paper deals with the three dimensional finite element simulation of rotary sinter-forging of cylindrical preforms using DEFORM-3D software. Aluminum sintered preforms were fabricated by the powder metallurgy route and basic experiments concerning simple compression tests were performed. The corresponding flow curve (stress-strain) data was added to the material library of the software. Further, the aluminum preforms were subjected to rotary forging operations and change in the preform relative density and diameter (preform top surface) with preform height reduction were recorded, plotted and analyzed. The distribution of total displacement, effective stress, effective strain and velocity plot in form of color codes and contours on the preform surface were obtained and critically analyzed. Also, the data for variation of radial displacement (preform top surface), die-preform interfacial contact area, average forging load with preform height reduction and forging time were recorded, plotted and analyzed.

Optimisation of machining TI6AL4V alloy: numerical simulation and experimental verification

The Ti6Al4V alloy is widely used in biomedical applications due to its good biocompatibility, low density, high corrosion resistance and high strength. The machining of this alloy poses several difficulties due to its unique mechanical properties and cutting characteristics. In the present study, a series of finite element simulations based on DEFORM-2D software were run and combined with response surface methodology in order to improve machining performance characteristics, i.e., cutting temperature, main cutting force and surface roughness of Ti6Al4V alloy by optimising the cutting parameters (viz. cutting velocity and feed rate) and tool geometry (viz. cutting edge radius and rake angle). Analysis of variances was employed to investigate the influence of cutting parameters and tool geometry on the machining properties. Mathematical models were developed to predict the responses. Finally, experimental verification was performed to check the validity of the numerical model that predicted responses within 8.4% maximum error.

Mechanical characterization of aluminium – red mud metal matrix composites

Red mud (bauxite residue) is an industrial waste obtained during the processing of alumina by Bayer’s process. In this work, an attempt has been made to utilize the industrial solid waste as the reinforcement material in aluminium metal matrix composites through powder metallurgy route. Red mud received from NALCO has been subjected to sieve analysis for micron level of 100 µm, 150 µm and 200 µm and milled to nano level of 42 nm using high energy ball mill. Micro and nano structured red mud powders and pure aluminium powder are mixed in a V-Blender, compacted at a pressure of 40 bar and samples are prepared by conventional sintering with vacuum as medium at different weight fractions of 2%, 4%, and 6% red mud. The paper presents mechanical characterization of pure aluminium with red mud such as hardness and compression strength and compression test results are validated with Deform-2D software. An increase in hardness and compression strength is observed with increase in the amount of percentage weight fraction of red mud. Hardness values variation depicts the information that nano red mud specimens have more hardness when compared with micro nature specimens. Hardness and compression strength properties are improved for nano level aluminium-red mud test specimen with 42 nm size and 6% weight fraction of Red mud.

Optimisation of machining TI6AL4V alloy: numerical simulation and experimental verification

The Ti6Al4V alloy is widely used in biomedical applications due to its good biocompatibility, low density, high corrosion resistance and high strength. The machining of this alloy poses several difficulties due to its unique mechanical properties and cutting characteristics. In the present study, a series of finite element simulations based on DEFORM-2D software were run and combined with response surface methodology in order to improve machining performance characteristics, i.e., cutting temperature, main cutting force and surface roughness of Ti6Al4V alloy by optimising the cutting parameters (viz. cutting velocity and feed rate) and tool geometry (viz. cutting edge radius and rake angle). Analysis of variances was employed to investigate the influence of cutting parameters and tool geometry on the machining properties. Mathematical models were developed to predict the responses. Finally, experimental verification was performed to check the validity of the numerical model that predicted responses within 8.4% maximum error.