Deform 3D v6.

Multiple Operations (MO3) System manual

8-15-2007

SFTC

Multiple Operations Template - 3D

Objective:
The purpose of this module is to allow the user to specify many sequential and often tedious tasks at the initial setup stage. The program will use this information at run-time to make changes between operations that can include process condition changes and tooling changes.

Characteristics:
Project based DEFORM-3D Multiple Operations is project based so that each simulation will be associated with a project directory. A project can be one or many consecutive operations. Each operation can be a change in tooling or a change the in process conditions or the addition of other objects. User interface The interface is an innovative mixture of an open system and a guided user interface. If the user desires, the user can navigate through sequentially through a list of menus to construct a simulation or the user can access menus in any sequence by selecting any item in a project list. Standalone program The navigation within this program is made through a single window. Tabs and buttons are available to direct the user to various points in the program including project set up, running the simulation and viewing the results.

Navigating the Program:

The program is divided into three different sections: The Pre-Processor, the Simulator and the Post-Processor. These three modes are can selected among each other through a tab selection. This can be seen in Figure 1. The Pre-Processor is used to construct a simulation, the results of the simulation are calculated in the Simulator section and the results are viewed in the Post-Processor. Each time a change is desired for a simulation, the change should be made in the Pre-Processor. The Simulator is where the simulation is performed and monitored. The Post-Processor has many tools for viewing the results of a

simulation and allow the user to better understand the process being simulated. A brief description of each is as follows:

Figure 1: The tab selector for determining the current mode is highlighted with a box

Pre-Processor There are several different ways of constructing a simulation. These different ways are: 1. Creating a new problem: A directory for this project is generated and the problem can be constructed from scratch. This can be done by selecting New Project under the File menu (See Figure 2). The step number for this is automatically set as 1. The process setting window, as seen below (See Figure 3), should appear on the screen. This window allows the user to insert various operations into the process list. In this process setting window, five operations such as Heat furnace, heat transfer, heat resting, deformation and heat dwelling can be added to the project tree. There is option to add objects other than default objects in any operation. The user can set the process parameters for each operation in process setting window itself. There are some default settings assigned for each operation which will seen in process settings window once you open the operation using Open opr, these settings can be modified by using Defaults Settings button.

a. Heat furnace: In heat furnace operation, heating of billet in a furnace is modeled. By default one object, workpiece, will be added to the project tree for this operation. b. Heat transfer: In heat transfer operation, heat transfer or heat loss to environment before workpiece/billet is placed on the die is modeled. By default one object, workpiece, will be added to the project tree for this operation. c. Heat resting: In heat resting operation, heat resting on the die prior to deformation is modeled. By default workpiece, top and bottom die objects will be added to the project tree. d. Deformation: Deformation of workpiece is modeled in this operation. The default objects are workpiece, top and bottom die. By default workpiece, top and bottom die objects will be added to the project tree. e. Heat dwelling: Heat transfer after deformation (after the dies retract from the workpiece) is modeled in this operation. By default workpiece, top and bottom die objects will be added to the project tree. 2. Editing an operation: The beginning of an operation of a simulation can be fully edited if the Open opr button is used on the negative step at the beginning of an operation. Editing an operation of a completed database will overwrite the results past this operation. 3. Adding a new operation: Adding a new operation means that the workpiece has either entered a new station or to receive a new blow from the tooling. This can be specified on a positive step after a simulation has been run. Any steps that occurred after this stage will be overwritten so the user should be cautious about the step to choose for adding an operation. 4. Continuing an operation: To select a positive step and clicking Open opr allows the user to modify only a limited set of data such as number of steps and stopping criteria.

Figure 2: Creating a new problem

Figure 3: The process setting dialog

The layout of the Pre-Processor is given in 4 sections. These sections are the display window, the project list window, project record window and the setting modification window. Display window The display window (See Figure 4) is where the objects in the simulation are viewed and geometric information is specified. The display window can display the following information based on selecting the tab seen in Figure 5. The available screens are: Graphic A graphical display of the current project. Summary A text summary of the current project listing process conditions, operation list information and current step information. Message A text file that gives detailed information about the last simulation run. In general, only the last few lines stating the reason for stoppage is of interest to the user. Log A text file that gives summary information of the overall progress of the last simulation run. As in the case of the message selection, only the last few lines stating the reason for stoppage are generally of interest to the user.

Functions that manipulate the DISPLAY window (such as Pan, Zoom, Magnify, and Rotate) can be activated using icons at the top of the Pre-processor window. These functions also have easy keyboard/mouse combination hotkeys that allow the user to quickly perform these functions without any excessive button clicking.
Display Icons

Icon

Function Pan

Description The objects in the DISPLAY window can be dynamically panned up, down, left, or right by moving the mouse while holding the left mouse button. (Shortcut: Shift + Left Mouse Button)

Zoom

The DISPLAY window can be dynamically zoomed in or out by holding the left mouse button and moving the mouse up or down. (Shortcut: Alt + Left Mouse Button)

Magnify

A portion of the DISPLAY window can to be magnified by clicking and holding the left mouse button at one corner of the zoom box and dragging the cursor to create a window encompassing the zoom area. (Shortcut: Ctrl + Alt + Left Mouse Button)

Rotate (unconstrained) The objects in the DISPLAY window can undergo an unconstrained rotation by holding the left mouse button. (Shortcut: Ctrl + Left Mouse Button)

Rotation about X-axis This icon allows the objects to be rotated about the X-axis in either the Object or Screen coordinate system.

Rotation about Y-axis This icon allows the objects to be rotated about the Y-axis in either the Object or Screen coordinate system.

Rotation about Z-axis

This icon allows the objects to be rotated about the Z-axis in either the Object or Screen coordinate system.

View Orientation Icons Isometric View YZ Plane View X-axis either pointing out of the screen (+) or into the screen (-) Y-axis either pointing out of the screen (+) or into the screen (-) Z-axis either pointing out of the screen (+) or into the screen (-)

XZ Plane View

XY Plane View

Figure 4: The display window of DEFORM-3D Multiple Operations. The red box shows where the parts will be displayed

Figure 5: The display window selector tab is highlighted by a red box

Project list window The project list window can be seen in Figure 6. The purpose of this window is to provide the user with a systematic list of required data for a given simulation. The data in the list is edited in the setting modification window (See Figure 9). The data that is being edited is controlled by the current active position within the project list window. An example of an active project list window is seen in Figure 7. The structure of the program will progress directly down this list by clicking Next in each menu. Alternatively, if any data needs to be modified, clicking at a given item in the list will allow that item to be edited in the setting modification window (See Figure 9).

Figure 6: The project list window. This shows the list that contains sets of simulation condition information

Figure 7: An active project list window

Project record window The project record window is used to show the current step being edited in the PreProcessor and can allow new operations to be started or to view the st. In an initial simulation, everything can be changed including the tooling geometry, environmental temperature and even the workpiece. When the simulation is being set up for the first time, the project record window looks like the area seen in Figure 8.

Figure 8: The project record window. This will show the current step of the simulation

Setting modification window As the project is being constructed most of the information is specified in the setting modification window (See Figure 9). By clicking next in the selection in this window will allow the user to traverse the project list in order. Each window will have an effect on how the simulation performs so care must be taken on each window. There are a couple of different ways in which information is inputted into the simulation. The different types of input are:

Radio buttons These selections require something to be specified for a given available set. For example, in Figure 10, the direction of movement of a moving die needs to be specified. The available choices are seen in Figure 10. Action labels These selections appear as blue text. These selections dont require selection but often require the user to select in order to set up the correct simulation. As seen in Figure 10, the movement controls can be defined more precisely by selecting these action items. Buttons These can be used to navigate between windows like forward or backward in the project list or to move to sub-option window for specifying advanced properties such as changing the environment temperature to model furnace heating. In figure 11, button allows the user to move forward or backward in project list. Checkboxes These selections can activate optional settings such as show geometry normal vectors. In Figure 11, a checkbox allows the user to see the geometry normal vectors of the object. Lists These selections are used when there are many available selections as in the case where a material has to be selected for a given object. There could be many materials possible and thus it is required that they can all be selected from a list.

Figure 9: The setting modification window. This will show where data is set for a given simulation

Figure 10: The movement control window

Figure 11: The geometry window

"Read from DB" This tells the system not to define any information for this object. The data for the object should be obtained from the previous operation available from the database. In cases where a part is moving through a multiple operation progression, each operation should keep the workpiece from the previous operation.

Figure 12: Window showing Read from DB option

"Skip this object in this operation" This tells the system not to apply any information for this object at this operation. Therefore when the simulation runs, this object will be empty of information until a later operation.

Figure 13: Window showing Skip this object in this operation option

"Append user defined keyword file" This tells the system to also read an optional keyword file when automatically setting up this operation. It is important to note that this advanced feature allows special, previously defined options to be applied between simulations.

Figure 14: Window showing Append user defined keyword file" option

Scheduled Positioning The Position object option allows the user to position an object that hasn't been specified as "Read from DB" (see Figure 15). The scheduled positioning is meant for cases where the object is "Read from DB". The workpiece is to be "Read from DB" and its position at this step is not certain so the positioning can only be scheduled. Bottom and top dies are scheduled to position by interference with respect to workpiece (see Figure 16).

Figure 15. The object positioning window. .

Figure 16: Adding scheduled positioning during deformation.

Add cycles
In order to repeat the operations in sequence, select the particular operation, (right mouse

click) and select Add cycles and specify number of cycles to be added. Project View will now generate additional operation data that user can now simulate (See Figure 17, 18 and 19).

Figure 17: Adding operation cycles.

Figure 18: Defining the number of cycles to add

Figure 19: Project tree after adding one cycle of deformation

Simulate Simulate is the section of the program where the simulation is executed. This feature is accessed through the tab list seen in Figure 1. The simulator appears in the lower, right region of the screen and looks like Figure 20. The three main options available are to run the simulation, stop the simulation, to monitor the progress through the process monitor and simulation graphics. When the simulation is finished, the simulation will be removed from the process monitor and will be listed as finished in the message file. In order to activate Use multiple processors option in simulate page, from Options menu select Environment. In Environment settings, go to Multiple Processors tab, activate Use multiple processors option and specify the Host name and number of processors.

Figure 20: The simulator window

Post-Processor The post-processor is used to view the results of a finished simulation. For a finished simulation, there are many steps available to view the result. To select the step to view, the steps list window in the Post-Processor is used (See Figure 21). After a step has been selected, the toolbox of viewing capabilities is available as seen in Figure 22. The available tools are similar to those in the DEFORM-3D.

Figure 21: The steps list of the Post-Processor

Figure 22: The toolbox for the Post-Processor

An overview of the tools is given below: Damage - Damage generally relates to the likelihood of fracture in a part. Damage is NOT a good indicator of fracture in tooling. Stress components should be used for die failure analysis. Damage has been shown to be a good indicator of certain types of tensile ductile fracture in cold parts (cracking due to deformation by stretching, such as chevron or surface cracking in extrusions, or cracking on the outside surface of an upset). It is not a good indicator of fracture in compression (such as splits perpendicular to die motion due to extreme heading reduction). The damage value at which fracture initiates varies substantially from material to material, and can even vary for a given material with different annealing treatments. However, for a given material with a given annealing treatment, critical damage value at fracture is reasonably repeatable. Effective strain - Strain is a measure of the degree of deformation in an object. A detailed description of strain is available in any standard text on mechanics of materials, metal forming analysis, or plasticity. A brief description of nomenclature will be given here.

Effective strain rate - Strain rate is a measure of the rate of deformation with respect to time. The units are strain per second where strain is a dimensionless value. The components of strain rate are defined in the same manner as the components of strain. Effective stress - Stress is defined as the force acting on a unit area of material. Assume a unit cube of material. Forces (or stresses) acting on the faces of the cube can be resolved into normal (perpendicular to the face) and shear (along the face). Velocity - The velocity option plots nodal velocity at each step. Vector plots display magnitude and direction. Magnitude is indicated by vector length and color. Contour plots display only magnitude, where contour color indicates velocity magnitude. Displacement - For small deformation problems only, plots the nodal displacement value. For large deformation, the displacement since the last remesh will be plotted. This variable is primarily intended for die deformation analysis. Normal pressure - Normal pressure is the force per unit area on the surface of an object. This is computed on the surface of slave objects. The range of values is from no stress to compressive stress. Tension cannot be maintained without some form of sticking applied between the surfaces. Temperature - The temperature plot displays nodal temperature at each step. State variables This menu (see Figure 23) allows for selecting from the available variables as well as selecting from the different plot methods. The available plot methods are: Line contour Draws equal divisions of the specified state variable with lines representing the regions where the state variable is of constant value. Shaded contour Draws the volume of material with equal divisions of shaded color where each color represents a region of constant value. Solid contour This is the same as shaded contour except each element does not interpolate the color between adjacent elements.

Vector plot - This is available for only velocity and displacement variables and shows the magnitude and direction of the values over the entire part as arrows. Deflection - This is available for the displacement variable and it shows a magnified view of how much the object has distorted from the beginning of a simulation. It is useful for cases where a die deflection is of interest but the actual motion is difficult to view unmagnified.

Figure 23: The state variables dialog

Simulation Summary - The step can be selected using the step list and then the object can be selected using the up/down arrow buttons in the object field. The information available through this dialog is maximum and minimum values as well as loads, speeds and volume.

Figure 24: Simulation summary dialog

Load/stroke curves The load/stroke window is used to generate load, speed, torque, angular velocity, energy, stroke and volume vs. time (or stroke or step or force) plots for the object. Multiple plots can be generated on the same graph. If time is used as the xaxis, then the graph can be used for selecting steps. Clicking on a point on the graph will load the nearest saved step from the database. Once the graph is on the screen, right clicking on it will allow the user to change how the graph appears on the screen.

Figure 25: Load-stroke window

Step selector The step options such as adding and subtracting steps from the Step List are accomplished from within this window.

Figure 26: Step selector dialog

Slicing The slicing dialog allows the user to cut a section into the workpiece. When the section is made, shaded contours can be seen in the cut area. The dialog appears in Figure 27. The cut section can be made by clicking on a line of the bounding box of the object. The default mode for a slicing plane is to define it by a point on which the plane lies and a vector that is normal (or perpendicular) to the slicing plane. In this selection, once a plane has been selected, the location of it can be changed by selecting the point value that corresponds to the normal direction of the plane and dragging the slider bar.

Figure 27: The slicing dialog

Point tracking In Point Tracking you can track more than 200 of points over the course of a simulation and view how they compare with each other. First select the desired starting step from the Start Step list in the Point Tracking window. Now select the object from the object table. Once you have done this, click on the Define Material Points button. You can now add the points that you wish to track in the Display window.

Figure 28: Point tracking data window

Adding Points Points can be added to track by clicking in the intended location with the left mouse button when this button is selected. Deleting Points Points can be deleted by clicking the third icon from the top in the Point tracking data window

Figure 29: Second window of point tracking wizard

Flownet - The flownet dialog allows the user to place some form (2D or 3D) of a grid onto the object and let the simulation track the deformation of the grid throughout the deformation. This is an excellent way in which to visualize any potential irregularities in the grain structure or to view potential surface defects. The flownet dialog window is seen in Figure 30. The following actions are required sequentially to view a flownet: 1. Select the starting and ending step (See Figure 30). Click Next when finished. By omitting steps, the time to compute the flownet calculations can be reduced but the user should not omit steps if the entire process is of interest. 2. Select the grid type to be used. Either 2D or 3D grids can be used. The 2D grids are less time-consuming for the same grid size since less information is required in two-dimensions. For this example, the grid selection is chosen and Next is clicked (See Figure 31).

Figure 30: Step selection dialog for flownet

3. For the 2D grid, a plane has to be defined by using a slicing plane (See Figure 32). The plane selection method is similar to the method used by the slicing dialog. After specifying a plane to be used, click Next. In other methods, there are comparable methods for defining the regions where a flownet is valid. 4. At this time, the density of the grid needs to be specified. In the case of the grid (See Figure 33), the number of grid can be set for a regularly spaced grid. By selecting preview the grid can be seen before calculating for all steps. After a desired grid is obtained, click Next. 5. At this time, advanced options are available such as saving either the beginning or end pattern (Figure 34). This is useful if a flownet from a different database is to be output to. Click Next when finished and the flownet will be calculated.

Figure 31: Grid selection window for flownet

Figure 32: Region definition for flownet

Figure 33: Grid definition for the flownet

Figure 34: Advanced options of the flownet

Note: Always define top die and bottom die at a time and never define bottom die geometry for top die and top die geometry for bottom die