1.

SHAPE ROLLING TEMPLATE 1-0

1.1. Creating a New Problem 1-0
1.2. Layout of Shape rolling template 1-1
1.3. Defining the Rolling Process 1-2
1.4. Defining Roll Pass Design 1-5
1.5. Defining Workpiece/Stock 1-7
1.5.1. Defining Workpiece/Stock Geometry 1-7
1.5.2. Generating Mesh For Workpiece/Stock 1-8
1.5.3. Defining Material & BCC For Workpiece/Stock 1-10
1.6. Defining Roll 1-10
1.6.1. Defining Geometry for Roll 1-10
1.6.2. Defining Material & BCC for Roll 1-12
1.6.3. Defining Angular Movement for Roll 1-13
1.7. Defining Pusher 1-14
1.7.1. Defining Geometry for Pusher 1-14
1.7.2. Defining Mesh for Pusher 1-15
1.7.3. Defining Material & BCC for Pusher 1-16
1.7.4. Defining Movement for Pusher 1-16
1.8. Defining Inter-Object Relations 1-17
1.9. Defining Step Controls For Pass1 1-18
1.10. Defining Inter-pass heat transfer 1-19
1.11. Defining a Second Pass and Starting the Simulation 1-21
1.12. Running the Simulation and Post-Processing 1-24
1.13. Exiting DEFORM-3D 1-24
1. Shape Rolling Template
1.1. Creating a New Problem
On a Unix machine, type DEFORM3 to open DEFORM-3D. On a Windows machine, go to
the button and select DEFORM-3D from the menu. The DEFORM-3D MAIN window
will appear, as shown below. Make a new problem under Problem directory. The problem
setup window will open.
Select the shape rolling guiding template as seen below and click .
Figure1.a: The problem setup window.
Select under problem home directory, name the simulation SHAPE_ROLL_Lab1 and click Finish.
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Figure 1.b: The problem setup window.
1.2. Layout of Shape rolling template
The layout of the interface can be seen in the figure below. The screen is distributed into four
discrete sections. The display window is where the objects for the current operation can be
viewed. The project list window is where the list of settings currently editable. Based on the
selection in the project list window, certain values can be edited in the setting modification
window. As information is provided to the interface, information will be printed in the project
record window such as saved steps.
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Figure 2. The layout of the shape rolling template interface
1.3. Defining the Rolling Process
The process setting window, as seen below, should appear on the screen. This window allows the
user to insert operations into the process list. Add two rolling passes and one heat transfer
operation (between two passes) to process (either drag rolling icon into project view or click add
to tree.) You can set the default settings for rolling or heat transfer operation before adding the
operations to the project.
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Figure 3: Process setting window
Close process setting window. Set the unit system to English. Click on the first operation in the
project view dialog and click open opr button to open the operation. Name operation Pass 1".
Select rolling type as Lagrangian (incremental rolling) (See Figure 4). Click Next. In the
thermal calculations page, select the "Calculate temperature in workpiece and rolls (non-
isothermal)" option. (See Figure 5) This option will enable us to calculate the temperature in rolls
also. Click Next.
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Figure 4: Selection of rolling type
Figure 5: Selection of Thermal caluclations
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Figure 6: The project view dialog with the rolling type selected.
Note: The shape rolling template supports the guided/open concept used by
many DEFORM products. As seen in Figure 5 , at any time during the problem
setup, the next or back buttons can be used to navigate to adjoining windows. In
addition, the Project View highlights the current position in the setup at any time.
1.4. Defining Roll Pass Design
In number of objects select Quarter symmetry & Main rolls (See Figure 7). In Roll Pass Design
we select to use the primitives. Select Round rolls with default dimensions and create the
geometry. A 2D sectional representation of the roll gap should be visible in the preprocessor as
seen in Figure 8. As you see only top roll is created because we assumed quarter symmetry for
this lab. Click close and then Next.
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Figure 7: Selection of objects.
Figure 8: Defining roll Geometry & 2D section of roll geometry created after definition.
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1.5. Defining Workpiece/Stock
Specify a workpiece temperature of 300 F. Choose the object length type as User defined with
length 20 inches. (see Figure 9) Click Next.
Figure 9: Defining workpiece object
1.5.1. Defining Workpiece/Stock Geometry
Select Use 2D geometry primitives for workpiece 2D cross-section. Pick the cylinder and make
the radius 4. (See Figure 10) Click Close and then Next.
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Figure 10: 2-D geometry primitives in the shape rolling template.
1.5.2. Generating Mesh For Workpiece/Stock
Use 90 elements in the 2D mesh for the workpiece cross-section and generate the mesh (See
Figure 11). For the workpiece 3D mesh, use number of layers as 72 & leave all other settings as
default and generate the 3D mesh. The 3D mesh looks like as shown in Figure 12.
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Figure11: Mesh settings along with the mesh
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Figure 12: Generated 3D mesh
1.5.3. Defining Material & BCC For Workpiece/Stock
In Material window, Click on import material from library and load AISI-1045_(20-1100C) data
from the DEFORM library. Click Next will take you to the BCC page. View the default
symmetry conditions & Heat exchange with environment surface assigned. The default conditions
are correct and hence we can go ahead , click Next.
1.6. Defining Roll
Specify a temperature of 100 F for the top roll (See Figure 13). Click Next.
1.6.1. Defining Geometry for Roll
At this point, the roll geometry created could be edited or a different geometry imported or a
different primitive can be selected & created if required. As the roll geometry is already defined,
and no changes are necessary, click Next go on to generate the 3D geometry for the roll with 108
uniform layers as seen in Figure 14. Click Next.
In geometry Surface Page select the symmetry surface as shown in Figure 14 and then click add.
Click Next.
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Figure 13: Defining Top Roll object
Figure 14: Three-dimensional image of the roll geometry.
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Generate 2D Mesh with 100 elements and 108 layers for 3D mesh. Generate Mesh, the mesh
looks like as shown in Figure 15. Click Next.
+Figure 15: 3D mesh & mesh settings for roll
1.6.2. Defining Material & BCC for Roll
In Material window, Click on import material from library and load D3 Material from the library. .
Click Next will take you to the BCC page .
In BCC Page select select symmetry BCC and select symmetry Surface as shown in Figure 16.
By default Heat exchange with environment is defined to all surfaces including symmetry surface
which is not correct, Hence delete the default definition and select all the surfaces except
symmetry surface shown in Figure 16 and then click button. Click Next
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Figure 16: Assigning Symmetry BCC
1.6.3. Defining Angular Movement for Roll
Assign a constant angular velocity of 55 rpm for top roll. (See Figure 17) Click Next.
Figure 17: Defining movement for roll
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1.7. Defining Pusher
Specify a temperature of 100 F for the pusher and a length of 1" & Check on the caluclate the
temperature option to calculate temperature distribution in the pusher as shown in Figure 18.
Figure 18: Defining Pusher object
1.7.1. Defining Geometry for Pusher
Click Next. Select Use 2D geometry primitives for pusher 2D cross-section. Pick the cylinder and
make the radius 5 as showin in Figure 19. Click Next. Generate 3D geometry with default
settings, the 3D geometry looks as shown in Figure 20. Click Next. Select symmetry surface as
shown in Figure 20. Click Next.
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Figure 19: Defining Pusher geometry
Figure 20: Symmetry Surfaces & 3D geometry of Pusher
1.7.2. Defining Mesh for Pusher
Generate 2D mesh with 100 elements & 3D mesh with 5 layers. The 3D mesh looks as shown in
Figure 21. Click Next
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Figure 21: 3D Mesh of the Pusher
1.7.3. Defining Material & BCC for Pusher
In Material window, Click on import material from library and load D3 Material from the library. .
Click Next will take you to the BCC page .View the default symmetry conditions & Heat
exchange with environment surface assigned. The default conditions are correct and hence we can
go ahead , click Next.
1.7.4. Defining Movement for Pusher
Select option Speed and assign a constant speed of 30 in/sec for pusher. (See Figure 22) The
preview of the movement can be seen by clicking on the "Preview Movement" option. Click next
will take you to Object Positioning but at this point the positioning is not required, so click Next.
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Figure 22: Assigning movement to Pusher
1.8. Defining Inter-Object Relations
In inter-object relations assigning coloumb friction of 0.5 and heta transfer coefficient of 5
between top roll and workpiece and for pusher assign coloumb friction of 0.3 and heta transfer
coefficient of 5. Click on button and "Generate all" contacts. (See Figure 22) The Generated
contacts looks as shown in Figure 23.
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Figure 22: Inter-Object relations
Figure 23: The contact generation between the roll and the workpiece.
1.9. Defining Step Controls For Pass1
Click Next. In step controls page set 5000time steps for this simulation with a step increment to
save as 25 & Time per step as 0.001 sec. For stopping criteria check on stopping plane & X
direction. Click on the free end of the stock .(see Figure 24) Click Next. Check the data and
generate the database. Click on "Close Oprn" button to close the operation Pass1.
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Figure 24: Stepping controls and Stopping criteria for Pass 1
1.10. Defining Inter-pass heat transfer
Highlight the second operation (which is a heat transfer) and click Open opr. You will see,
automatically generated workpiece (See Figure 25) with uniform cross-section. It uses the
approximate exit cross-section of the first pass. But in during run it uses the actual exit cross-
section to generate workpiece for heat transfer operation. Click Next until you reach Heat
Condition Page.
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Figure 25: Workpiece generated for heat transfer operation
Go to Heat Condition page and input transfer time as 10 sec and environmnet temperature as
68 F. Use other default values (See Figure 26).
Figure 26: Definition of Heat Condition
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Go to Step Controls page and put 10, 2 and 1for Number of steps, Step increment and time per
step respectively. Close the heat transfer operation.
1.11. Defining a Second Pass and Starting the Simulation
Highlight the third operation and Click on "Open Oprn" button. Name the operation as Pass 2.
Click next until you reach Roll pass design page. Click on "Use Primitives for Main Roll Pass
Design" and then select the flat type with roll gap of 6.5 in and leave other values default. (see
Figure 28) Once the roll section is selected and created a 2D sectional view appears as shown in
Figure 29.
Figure 28: Creation of Flat Roll
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Figure 29: A 2D sectional view of set up after creation of Flat Roll
Click Next Until you reach roll object page. Specify a temperature of 100F for the top roll. Click
Next. As the roll geometry is already defined, and no changes are necessary, go on to generate the
3D geometry for the roll with 108 uniform layers as seen in Figure 30.
In geometry page select symmetry Surface other than the surfaces shown in Figure 30.
Generate 2D Mesh with 100 elements and 108 layers for 3D mesh. Generate Mesh, the mesh
looks like as shown in Figure 31. Click Next.
In BCC Page select symmetry BCC and select symmetry Surface other than the surfaces shown in
Figure 30. By default Heat exchange with environment is defined to all surfaces including
symmetry surface which is not correct, Hence delete the default definition and select the surfaces
as shown in Figure 30 and then click button. Click Next
Assign a constant angular velocity of -55 rpm.
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Figure 30: Three-dimensional image of the roll geometry.
Figure 31: View of the Meshed Flat Roll
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Use same settings for the pusher as for Pass1. In object positioning page, Click Add to invoke the
object positioning window. Schedule the interference positioning of the Top Roll with the work
piece in -Z direction & Pusher in +X direction with a tolerance of 0.0001. (See Figure 32)
Use the same step definition settings as for pass 1 & for stopping controls select the free end of
the stock and check on -X direction as the stock is moving in -X direction. Close the operation
(master file will save when operation is closed). Close out of the shape rolling template.
1.12. Running the Simulation and Post-Processing
Exit the shape rolling template. In GUI main select the DB & under simulator click on Run. The
simulation will be started. Simulation Graphics to see the results simultaneously as simulation
runs. Post-Processor can be used to view the results.
1.13. Exiting DEFORM-3D
Click the Exit icon. Once you are back in the MAIN window, you can exit DEFORM-3D by
selecting File Quit or by clicking . When asked whether you want to quit, click
.