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Deform 3D v6.1 Shape Rolling System Manual 8-15-2007 SFTC
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deform 3d shape rolling

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Page 1: deform 3d shape rolling

Deform 3D v6.1

Shape RollingSystem Manual

8-15-2007

SFTC

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Shape Rolling Template

Objective:

The objective of this document is to provide a brief overview of the interface of ShapeRolling template.

System:

A listing of the system overview is as follows:

1. The work piece or rolling stock is object 1, rolls and other components are thefollowing objects.

2. The rolling stock is of rigid-plastic type.3. Model preview is available for interactive setup of multi pass conditions.4. The rolls are rigid objects during for the rolling simulations.5. Rigid rolls can handle non-isothermal conditions.6. Meshing controls, and remesh procedures for brick elements.7. The rolling direction is along global X-axis.8. Side rolls can be defined with specific movement controls.9. Support tables can be defined including thermal interaction with work piece.10. Automatic stopping criteria for ALE and Lagrangian models11. Inter pass thermal and strain variations can be modeled.

Characteristics:

Project based

The Shape Rolling Template is project based in which each simulation will be associatedwith a project directory. A project can consist of a single operation or contain multipleoperations that occur on a single rolled stock. Each operation can be either a change inroll geometry, roll gap, roll speed, workpiece orientation or a heat transfer operation.

User interface

The interface is an innovative mixture of an open system and guided user interface. If theuser desires, navigation can be sequential, via a list of menus to construct a simulationdata; alternatively, the user can access menus in any sequence by selecting any item in alist. Running the simulation and Post-Processing the results is carried out via the standardDEFORM™-3D features.

Navigating the Template:

The template is used to construct a simulation, load a step from a previously runsimulation, add operations and view summary, message and log files.

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Figure 1: A snapshot of the interface showing the step list of a previously run database, therolls, side rolls, table, pusher and stock and the tree containing a single operation.

Pre-Processor

There are several different ways of constructing a simulation. These different ways are:

1. Creating a new problem – A directory is generated and the problem can beconstructed from scratch. This can be done by selecting New Problem under theFile 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 thescreen. This window allows the user to insert operations into the process list.

2. Editing a new problem – The beginning of an operation of a simulation can befully edited if the Open opr button is used on the negative step at the beginning ofan operation.

3. Adding a new operation – Adding a new operation means that the stock is toundergo an additional roll pass or heat transfer.

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Figure 2: Creating a new problem.

The process setting window, as seen below Figure 3, should appear on the screen. Thiswindow allows the user to insert various operations into the process list.

Figure 3: The process setting dialog

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The layout of the Pre-Processor is given in 4 sections. These sections are the displaywindow, project list window, project record window and the setting modificationwindow.

Display window:

The display window (See Figure 4) is where the rolls and workpiece are viewed andgeometric information is specified. The display window can display the followinginformation based on selecting the tab seen in Figure 4. 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 are of interest to the user.

• Log – A text file that gives summary information of the overall progress of thelast simulation run. As in the case of the message selection, only the last fewlines are generally of interest to the user.

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

Display Icons

Icon Function Description

Pan The objects in the DISPLAY window can bedynamically 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 zoomedin or out by holding the left mouse button and moving the mouse up or down.

(Shortcut: Alt + Left Mouse Button)

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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 theX-axis in either the Object or Screen coordinatesystem.

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

Rotation about Z-axis This icon allows the objects to be rotated about theZ-axis in either the Object or Screen coordinatesystem.

View Orientation Icons

Isometric View

YZ Plane View X-axis either pointing out of the screen (+) or into the screen (-)

XZ Plane View Y-axis either pointing out of the screen (+) or into the screen (-)

XY Plane View Z-axis either pointing out of the screen (+) or into the screen (-)

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Figure 4: The display window of Shape Rolling. The red box shows where the stock androlls will be displayed.

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

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Project list window

The project list window can be seen in Figure 6. The purpose of this window is toprovide a systematic list of required data for a given simulation. The data in the list isedited in the setting modification window (See Figure 9). The data that is being edited iscontrolled by the current active position within the project list window. An example ofan active project list window is seen in Figure 7. The structure of the program willprogress directly down this list by clicking Next in each menu. Alternatively, if any dataneeds to be modified, clicking at a given item in the list will allow that item to be editedin the setting modification window (See Figure9).

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

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Figure 7: An active project list window.

Project record window

The project record window used to show the step to be edited in the Pre-Processor. Oncean operation is opened for modification, the project record window shows a statusdialogue.

Figure 8: The project record window. This will show the current step of thesimulation or status dialogue.

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Setting modification window

As the project is being constructed most of the information is specified in the settingmodification window (See Figure 9). Clicking Next in this window will allow the user totraverse the project list in order. Each window will have an effect on how the simulationperforms. There are a number of different ways in which information is inputted into thesimulation. The different types of input are:

• Radio buttons – require something to be specified. For example, in Figure 10, themeshing parameter needs to be specified. The available choices in this case are“uniform thickness of layers” and finer mesh in the contact region”

• Action labels – appear as blue text. As seen in Figure 10, the action labelgenerates a 3D mesh in the workpiece.

• Buttons – used to navigate back and forth in the project list and for advancedgeometry setup and opening/closing operations. Figure 11 shows the buttons usedto navigate back and forth in the project list.

• Checkboxes – activate optional settings such as adding objects or parameters. InFigure 11, a checkbox allows the user to select additional side rolls, a pusher andif quarter symmetry is to be used.

• Lists – used when there are many available selections as in the case of materialselection.

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

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Figure 10: Mesh generation in the workpiece.

Figure 11: The object selection window.

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Rolling type

The rolling template has two different rolling types. One is steady state ALE rolling andother is Lagrangian (incremental) rolling.

Figure 12: Rolling type selection window

Thermal Calculations

In thermal calculations page (see Figure 13) options are available for selectingcalculations in workpiece alone or even in dies in case of non-isothermal or at constanttemperature in case of isothermal.

Figure 13: Thermal calculations selection page.

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Model Type

In model type page (See Figure 14) depending on the problem we have options to selectfull model or half symmetry or quarter symmetry. The objects required to set up theprocess can be selected by checking the respective check boxes.

Figure 14: selection of model type and number of objects.

Roll pass design

This roll pass design feature enables us to define the different roll designs for main andside rolls. Several pre-defined roll designs are available for user to select else user has anoption to create rolls from primitives.

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Figure 15: Roll Pass design

Figure 16: Main roll Pass design

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Figure 17: Side roll Pass design

Workpiece length

User can define the length of the stock or can use the default length set by system (seeFigure 18).

Figure 18: workpiece length definition

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Geometry-2D

The sectional geometry of the stock can be imported from a file or can be created fromthe primitives. The modifications to the imported or created geometry can be made using“ Edit 2D geometry” option. The geometry can be saved using “ Save 2D geometry”option.

Figure 19: 2D geometry cross-section definition page.

Geometry –3DIn this template a 2D geometry will be revolved depending on the model set up in numberof objects page to create 3D geometry. In Geometry –3D page the user can see thedigitized 2D geometry that will be used to create 3D geometry using preview digitized 2Dgeometry option. The user has an option to create 3D geometry with finer polygons at thecontact or uniform geometry through out the object.

Figure 20: 3D geometry definition page

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Meshing

A 2d mesh will be created which will be extruded / revolved to the length of the object.Number of layers can be increased to have finer mesh in 3D. The fine mesh can becontrolled by entering starting and ending points of the desired region. (See Figure 21)

Figure 21: 3D Meshing Parameters

Boundary conditions

The boundary conditions for workpiece and rolls are automatically assigned. If userwants to change the boundary conditions, he can modify the boundary conditions.

Figure 22: Boundary conditions

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Movement control

The movement for rolls can be specified either by Angular Velocity or Torque. Either ofthem can be defined as constant or function of time or function of angle.

Figure 23: Movement controls of rolls

Stopping criteriaStopping criteria to stop the rolling process can be specified by setting a co-ordinate in+X or –X direction, after all nodes of workpiece crosses the particular defined point thesimulation stops for that pass. Stopping criteria option is available in lagrangian(incremental) rolling only while in ALE the simulation will be stopped once the steadystate is reached with respect to gradients of the state variables reaching the exit section.

Figure 24: Stopping criteria definition

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Schedule to align workpiece to the X axis

For easy and automatic setup of multi pass models, where in the workpiece shape maynot remain straight as it heads to generate the data needed for the subsequent pass. Thiskind of workpiece distortion could be a result of basic roll pass design, and table positionas well. This feature attempts to automatically generate data with correct alignment ofdeformed workpiece from one pass to the next in case of Lagrangian model. Figure 25shows the automatic alignment of workpiece to the X axis.

Figure 25: Automatic alignment of workpiece

Scale strain to simulate retained strain between passes

This functionality allows user to define a table data of strain and retained strain, where byuser can scale (or map) the end results of one pass (strain) while preparing the data forthe subsequent pass. This will enable users to model the process conditions like strainrecovery at high temperatures,(when users have the measured data) when there is adefinite heat transfer time between two rolling passes, and inter pass strain reductionneeds to be accounted for. Figure 26 shows the strain scaling function option enabled tosimulate the retained strain between passes.

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Figure 26: Strain scaling function to simulate retained strain between passes.

Meshing between passes

User can force remesh of the stock by selecting the option Force remeshing.

Figure 27: Meshing between passes

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Simulator

The standard DEFORM-3D simulator is used to perform the simulation

Post-Processor

The standard DEFORM-3D Post-processor is used to view the simulation results