DEFORMTM 3D Software Research Articles

The simulation and experimentation of spiral flat bottom engraving

The study uses rigid-plastic finite element (FE) DEFORM TM 3D software to investigate the plastic deformation behaviour of spiral flat bottom engraving. The finite element analysis assumes that the spiral flat bottom is a rigid body. During the engraving process, the deformation causes an increase in temperature and wear inside the blank. The FE analyses investigate the effects of cutting speed, depth of cut, and the feed of the workpiece on the damage, effective strain, stress, temperature, and wear induced within the workpiece. The simulation results confirm the suitability of the DEFORM TM 3D software for modelling the spiral flat bottom engraving. Comparisons of engraving of spiral flat bottom with clockwise and counter-clockwise have been performed. The analysis of following stress-strain simulation has been predicted by machine learning in this study. Eventually, the experiment of spiral flat bottom engraving is used.

Investigation of Cold Extrusion of Aluminum AA 2024 Alloy using Finite Element Analysis

In recent years, the interest in modeling extrusion processes has resulted in the development of several analytical and numerical methodologies. The present work optimizes cold extrusion process variables (Die angle (DA), Ram speed (RS), Coefficient of friction (CoF)) on extrusion force, displacement, damage and time for the Aluminum AA 2024 alloy material. DEFORMTM-3D software is used to carry out numerical simulations and to study the behavior of the Aluminum AA 2024 billet during the plastic deformation over the conical die. The die/ container and ram (top die) are considered as rigid bodies and the room temperature is maintained during the extrusion process. The simulations are conducted as per L27 Taguchi orthogonal array. The obtained results are analyzed in ANOVA. An optimization using multiple variables is performed by grey relational analysis (GRA). The highest grey relational grade (GRG) is obtained for experiments conducted at DA level 2, RS level 2, and CoF level 3 (minimum extrusion force, damage and time) and (maximum displacement) is achieved by GRA. Systematically, the influence of the ram speed, coefficient of friction, and die angle are examined. The damage factor is considerable at 30° DA under the ram speed of 3mm/min.

CAD/CAE/CAM을 활용한 금형형상 가공에 관한 연구

The purpose of this study is to investigate the relationship between the surface roughness and cutting force for the die shape and factor change using CAD/CAE/CAM. RPM, feed rate, and step over were chosen as the main factor for cutting force. To estimate the correlation between cutting force and surface roughness, cutting force was predicted using the DOE(design of experiments) and DEFORMTM-3D(software of finite element analysis), surface roughness was measured through experiments. The optimal level for each factor was considered, and the most effective factor was evaluated using the Taguchi method(one of DOE). In this study, the machining conditions to obtain a particular surface roughness based on the measured value were derived.

Investigation on deformation of Inconel alloy 751

In the present work, effect of strain rate on the simulation of forging deformation of Inconel alloy 751 steel has been done. Finite Element Analysis and Modeling carried out on the Deform™-3D software. The deformation simulation was done on the various strain rates of 1.9 s−1, 2 s−1 and 3 s−1 at the higher temperature of 1050 °C. The simulation is carried out at 10 mm/sec upper die speed considering the Coefficient of friction as 0.3 N. Distribution of temperature, load, stress and strain obtained from different strain rates are shown and discussed. The stress and strain distribution displayed diverse dissemination, signifying inhomogeneity throughout hot forging. As the strain rate increases the inhomogeneity in the deformation behaviour is reduced.

Neural Network and Genetic Algorithm Based Finite Element Model for Optimal Die Shape Design in Al-1100 Cold Forward Extrusion

This paper employs rigid-plastic finite element DEFORMTM 3D software to estimate the plastic deformation behavior of an aluminum billet during its axisymmetric extrusion through a conical die. The die and container are assumed to be rigid bodies and the temperature change induced during extrusion is ignored. The important parameters which effect on the extrusion process were assumed to be: the reduction of area (0.75), semi- cone die angles (5, 6, 7, 8, 10, 12, and 14o) coefficient of friction is 0.05 and the extrusion speed is 250 mm/s. Under various extrusion conditions, the present numerical analysis estimates the stresses, the die load and the flow velocity of the billet at the die exit. Genetic algorithm coupled with neural network is employed to find optimum die angle leading to minimum stresses without any constraint. The simulation results confirm the suitability of the current finite element software for modeling the three-dimensional cold extrusion of aluminum rod.

Grey-based Taguchi method for optimisation of hot forging of connecting rod

In this paper, three dimensional finite element analysis has been carried out using FEM-based DEFORMTM 3D software on hot forging of connecting rod. The influence of design parameters and process parameters are investigated for the responses like effective strain rate and forging load during forging operation. In order to optimise both the responses simultaneously, grey relational analysis (GRA) embedded with Taguchi method is employed. Grey relational grade is used as a performance index to determine optimal setting of process parameters for both the responses simultaneously. Analysis of variance (ANOVA) is employed to determine significant parameters. Process parameters such as flash thickness, flash width, and corner radii are found to be the most significant parameters affecting grey relational grade. Optimal process setting leading to a higher effective strain rate with the least forging load has been verified through a confirmation experiment for validation of the results. [Received 15 October 2015; Revised 25 February 2016; Accepted 13 March 2016]

Relationships between the process conditions and microstructures evolution for extrusion-shear of magnesium alloy

It is widely recognized that grain refinement has significant influences on the strength and ductility of metals. To improve the industrialization of the severe plastic deformations (SPD) technologies for magnesium alloy, a new extrusion-shear (ES) method has been explored and widely investigated because it can manufacture ultra-fine grained microstructures in magnesium alloys. It is crucial to research the effects of process parameters on the deformation behaviors of ES process. Three-dimensional (3D) finite element modeling of ES processes with different billet temperatures and channel angles have been researched. Different billet temperatures have been regarded as the initial conditions in DEFORMTM-3D software. The strain rates evolutions have been gained with different ES process conditions. The microstructure evolution has been analyzed by the simulation and experimental results. The decreases of billet temperatures and channel angles could improve the grains refinements of magnesium alloys which have been prepared by ES process. The simulation and theoretical analysises results showed that reasonable billet temperatures and channel angles could promote grains refinements. Research results could present the fundamentals and practical guidelines for the designs of ES dies and optimization of process parameters to manufacturing high-performance magnesium rods.

Robust Design on Equal Channel Angle Extrusion of Ti - 6Al - 4V Using Taguchi Method

This paper employs the rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of Ti-6Al-4V titanium alloy during ECAE extrusion forming processing. Under various ECAE extrusion forming conditions, the FE analysis investigates punch load distribution and the effective strain distribution. A series of simulation analyses, in which the variables relied on different of the internal angle between the two die channels, the friction factors, the titanium alloy temperature and the strain rate of billet, were run to examine die radial load distribution when equal channel angle extrusion. Finally, we used the Taguchi method to determine the best design parameters. In the design process, our results confirmed the suitability of the FE method and the manufacturing process for titanium alloy forming.

A Grey-based Taguchi Method to Optimize Hot Forging Process

In this study, Three dimensional finite element analysis has been carried out using FEM based DEFORMTM 3D software on hot forging of spring saddle. The influence of design parameter viz. flash thickness and process parameters viz. billet temperature, die temperature and friction coefficient along with their interactions are investigated for the responses forging load and billet temperature loss during hot forging operation using Taguchi's L27 orthogonal array. Analysis of variance (ANOVA) is employed to determine significant parameters. It has been observed that optimal factor settings for each performance characteristic are different. Flash thickness and Billet temperature and interaction of flash with billet temperature are observed as the most significant parameters affecting the responses. In order to minimize two responses simultaneously, Grey Taguchi method is adopted and optimum factor levels have been reported. Optimization of the process parameters simultaneously leading to a low billet temperature loss along with a low forging load and it is also verified through a confirmation experiment for validation of these results. Confirmatory results prove the potential of Taguchi design of experiments, ANOVA analysis and Grey Taguchi method in Multi-objective optimization of process parameters.

An investigation into the homogeneity of microstructure, strain pattern and hardness of pure aluminum processed by accumulative back extrusion

The present work focuses on the evolution of microstructure and mechanical characteristics of commercially pure aluminum during accumulative back extrusion (ABE) processing. The electron backscatter diffraction (EBSD) analysis and microhardness measurements were utilized to study the effect of pass number and deformation route on the microstructure and hardness across the ABE-processed specimens. The distributions of effective strain and shear stress during ABE were studied using finite element analysis with DEFORMTM 3D software. The results demonstrated that an effective plastic strain of about 2 was introduced after each separate pass of ABE. This process produced a high-strength ultrafine-grained material where the grain refinement was attributed to the shearing and/or mechanical subdivision of the initial coarse grains along with dynamic restoration processes. The distributions of both the simulated strain and the measured microhardness were inhomogeneous after the first ABE pass, but thereafter outstanding hardness homogeneity was achieved when the consecutive ABE passes were applied. Moreover, the application of the reversing route was found to introduce a high level of hardness homogeneity after each applied ABE pass.

Die Stress Optimization Using Finite Element and Taguchi Method

In this study, finite element simulation and the Taguchi method are employed to optimize the die stress in hot closed die forging process. Investigations are carried out for forging of automotive spring saddle by including all realistic process parameters. The research involved analyzing the effects of flash thickness, billet temperature, die temperature and friction coefficient on effective die stress by means of computer simulation. To obtain the result the forging process was modeled in CATIA V5, 3D Solid Modeling Software, simulated in DEFORMTM 3D Software, and statistically setup and examined using Taguchis orthogonal array. Analysis of variance (ANOVA) is employed to determine significant parameters.

Taguchi Method and Genetic Algorithm Neural Networks Analysis of Forging Process of Bicycle Chain Wheel

Recent years due to the rise of awareness of environmental protection and energy conservation are attention. Which is the most representative of the bike. Many processing factors must be controlled in the bicycle chain wheel. This study employed the rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of an aluminum alloy workpiece as it is forged for bicycle chain wheels. Factors include the temperature of the forging billet, shear friction factor, temperature of die and punch speed control all parameters. Moreover, this study used the Taguchi method and Genetic algorithm neural networks to determine the most favorable optimization parameters. Finally, our results confirmed the suitability of the proposed design, which enabled a bicycle chain wheel die to achieve perfect forging during finite element testing.

Study of Forging Forming of 7075 Aluminum Alloy Bicycle Pedal

Forging is simple and inexpensive in mass production. Metallic materials are processed through plastic deformation. This not only changes the appearance but also changes the internal organization of materials that improve mechanical properties. However, regarding manufacturing of plastic products, many processing factors must be controlled to obtain the required plastic strain and desired tolerance values. In this paper, we employed rigid-plastic finite element (FE) DEFORMTM software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it used to forge bicycle pedals. First we use Solid works 2010 3D graphics software to design the bicycle pedal of the mold and appearance, moreover import finite element (FE) DEFORMTM 3D software for analysis. The paper used rigid-plastic model analytical methods, and assuming mode to be rigid body. A series of simulation analyses in which the variables depend on different temperatures of the forging billet, round radius size of ram, punch speed, and mold temperature were revealed to confirm the predicted aluminum grain structure, effective stress, effective strain, and die radial load distribution for forging a bicycle pedal. The analysis results can provide references for forming bicycle pedal molds. Finally, this study identified the finite element results for high-strength design suitability of a 7075 aluminum alloy bicycle pedal.

Precision Forging Technological Optimization for 7075 Aluminum Alloy Complex Component with Limbs

Aluminum alloy complex components with limbs, such as antitorque arms, are difficult to manufacture because of their complicated shapes and high requirements in terms of mechanical properties. To form 7075 aluminum alloy antitorque arms precisely, two forming schemes with different billet shapes were used to simulate the precision forming process and study the metal flow laws using DEFORM™-3D software. The simulated results show that the second forming scheme (with a two preformed limb billet) significantly improved the metal filling formability and flowing uniformity compared with the simpler solid billet case. Moreover, this scheme also significantly increased material utilization, and the required forming load was only 30% of the first scheme. The experimental results also showed that this scheme can obtain the necessary component with dimensional accuracy and quality in good agreement with all the technical requirements.

Simulations of isothermal ECAE for magnesium alloy using FEM software and experimental validations

It is important to research the effect of die structures parameters for equal channel angular extrusion (ECAE) on the deformation behavior, strain distribution and loads requirement. ECAE is an extrusion process widely researched for its potential to produce ultra-fine grained microstructures in magnesium alloys. In this paper some three-dimensional (3D) geometric models with different corner angles 90° and 135° and with fillets or not in the bottom die were designed by UG software. Some important isothermal process parameters were regarded as basal conditions used in DEFORM™-3D software such as temperatures, the friction coefficient, and extrusion speed. The deformation heterogeneity of ECAE was analyzed from the simulation and experimental results. The deformation homogeneity caused by the EACE die with fillets was improved comparing with the die without fillets. But the cumulative maximum strains decreased. The requirement extrusion force decreased with the fillets and channel angle increase in ECAE die. From the simulation and experimental results the smaller channel angle can obtain the higher cumulative strains and produce tinier subgrains. The loads of top die decrease mainly with fillets. The ECAE die with the channel angle 90° and fillets is good to improve the plasticity and deformation homogeneity of the billets if the extrusion force is enough. It was demonstrated that the simulation results were in good agreement with experimental results and the theoretical calculation.

A Study on the Cellphone Cover-Forming Process of Titanium Alloys Using the Finite Element Method

In recent years, the style of 3C products demanded thin and small results due to gradual trends, though most of the industry is forming a continuous manner of stamping. However, the material thickness cannot be changed in products. This paper employs the rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of titanium alloy (Ti-6Al-4V) workpiece for the forming processes of cellphone covers. In addition, this study utilizes the Solid Work 2010 3D graphics-rendering software for modeling, which is simulation software used to import various forming process conditions. The software analyzes the effective strain, the effective stress, critical damage value, and the die radius load distribution of the work-piece. Furthermore, this study used simulative software to analyze its forming processes for changes in grain size of the microstructure. The analytical results confirm the suitability of the current finite element software for forming processes of cellphone covers.

Rigid-Plastic Finite Element Analysis of Cross Wedge Rolling

In the cross wedge rolling process, many factors must be controlled to obtain the required plastic strain and desired tolerance values. The major factors include the wedge relative velocity, the forming angle, the spreading angle, and sectional reduction. This paper uses rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it is processed for cross wedge rolling. This study analyzes the effective strain, the effective stress, and the X-axial load distribution of the workpiece under various rolling conditions. Furthermore, using simulation software to analyze the changes to the microstructure by the rolling process, this study presents analytical results that confirm the suitability of the current finite element software for cross wedge rolling.

Finite element analysis of superplastic blow-forming of Ti-6Al-4V sheet into closed ellip-cylindrical die

Utilizing commercial DEFORM TM 3D finite element (FE) software, this study performs a series of numerical simulations to investigate the superplastic blow-forming of Ti-6Al-4V titanium alloy into a closed ellip-cylindrical die. In performing the simulations, it is assumed that the die is a rigid body and the titanium alloy sheet is a rigid-plastic material with homogeneous and isotropic properties. The simulations focus specifically on the respective effects of the shear friction factor, the die entry radius, the die height and the die’s short-axis length on the thickness, effective stress, effective strain and critical damage distributions within the blow-formed product. Overall, the simulation results confirm the suitability of the DEFORM TM 3D software for modelling the superplastic blow-forming of Ti-6Al-4V titanium alloy.

Die structure optimization of equal channel angular extrusion for AZ31 magnesium alloy based on finite element method

Three-dimensional(3D) geometric models with different corner angles (90° and 120°) and with or without inner round fillets in the bottom die were designed. Some important process parameters were regarded as the calculation conditions used in DEFORM TM-3D software, such as stress—strain data of compression test for AZ31 magnesium, temperatures of die and billet, and friction coefficient. Influence of friction coefficient on deformation process was discussed. The results show that reasonable lubrication condition is important to plastic deformation. The change characteristics for distributions of effective stress and strain during an equal channel angular extrusion (ECAE) process with inner angle of 90° and without fillets at outer corner were described. Inhomogeneity index ( C) was defined and deformation heterogeneity of ECAE was analyzed from the simulation and experiment results. The deformation homogeneity caused by fillets at outer corner increased compared with the die without fillets. The cumulated maximum strains decrease with increasing the fillets of outer corner in ECAE die and the inner corner angle. The analysis results show that better structures of ECAE die including appropriate outer corner fillet and the inner corner angle of 90° for the die can improve the strain and ensure plastic deformation homogenization to a certain extent. The required extrusion force drops with increasing the fillet made at outer corner in ECAE die. It is demonstrated that the prediction results are in good agreement with experiments and the theoretical calculation and the research conclusions in literatures.

Investigation into cold extrusion of aluminum billets using three-dimensional finite element method

Abstract This paper employs rigid-plastic finite element DEFORM™ 3D software to investigate the plastic deformation behavior of an aluminum billet during its axisymmetric extrusion through a conical die. The die and container are assumed to be rigid bodies and the temperature change induced during extrusion is ignored. Under various extrusion conditions, the present numerical analysis investigates the stress–strain distribution, the damage factor distributions, the die load and the flow velocity of the billet at the exit. The relative influences of the semi-angle of the die, the extrusion ratio and the friction factors are systematically examined. The simulation results confirm the suitability of the current finite element software for modeling the three-dimensional cold extrusion of aluminum billets.