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Advancements of Extrusion Simulation in Deform-3D
Advancements of Extrusion Simulation in Deform-3D
DEFORM-3D
By G. Li, J. Yang, J.Y. Oh, M. Foster, and W. Wu, Scientific Forming Tech. Corp.; and P. Tsai and W. Chang, MIRDC
Introduction
(2)
Where n+1 is the convected strain with respect to the
CRS. The variable L is the material strain and Nr is the
total number of the surfaces between this element, with
volume V, and the contiguous elements, whose strain is
denoted by the superscript c. Also required for the calculation is
(3)
As pointed out by Rodriguez-Feran, et al., the time step
t should not be too large as to bring a particle to cross
an entire element at the speed of the convective velocity
c. Figure 3 shows some examples of ALE simulations. The
profiles were designed to show the capability of predicting extrudate distortion.
Industrial Example
The updated CRS and MRS are no longer superimposed at this point. However, after the updated CRS is
obtained from the updated MRS, the latter can be discarded. The simulation of the next incremental step uses
the updated CRS and finishes with a new updated MRS.
With this ALE mesh design and updating scheme, a stable contact definition between the billet and the dies is
maintained.
State Variable Update: In the ALE procedure, it is necessary to update the state variables when mapping them
from the MRS to the CRS. Theoretically, the convection
of the state variables, say, the effective strain, is based on:
(1)
Difficulty arises when calculating the gradient terms of
the elemental state variables, as they are defined at the
integration point(s) of each element and are therefore
only piecewise continuous. Two approaches can be found
in the literature: interpolation and convection. The interpolation method updates the nodal coordinates as
well as the state variables in the MRS, and then maps the
state variables to the CRS.6 The convection method solves
Eq. (1) to update the state variables. The Godunov-type
update proposed by Rodriguez-Feran, et al.,7 belonging
to the second group, is used in this work. To obtain the
effective strain of a particular element with respect to the
CRS, a surface integration containing a flux is considered by:
Figure 3: ALE simulation examples. Top Row: T-shaped; Bottom Row: step-shaped.
ended up longer than the outer four. The press load increased substantially as the welding chamber filled, and
the extrudate began to form. The internal ribs were the
final feature of the cross-section to form as the extrudate
came out of the die.
In an updated Lagrangian extrusion simulation, the
workpiece mesh deforms and extrudes through the dies.
Due to the extensive deformation at the die corners,
remeshing of the workpiece was a common occurrence.
Self-contact of the merging flows in the welding chamber also contributed to remeshing. When the four outer
flows had essentially merged in the welding chamber, the
self-contacting surfaces between the flows were manually
removed to speed up the simulation (Figures 7-8).
Extrusion Experiment: An extrusion experiment was performed for comparison with the simulated results. A 350ton forward extrusion press was used (Figure 13). Table
II shows the experimental conditions. Two initial billet
lengths were used in the experiment. The maximum
load for the 100 mm billet was 220 SI tons, while the max
load for the 200 mm billet was 350 SI tons. The billet
length directly affects the friction with the container wall.
Often, shorter billets are preferred in real applications
in order to control the load, temperature distribution,
quality, etc. Figures 14 and 15 are photos of the extrudate
taken in the experiment. The slightly burgeoning shape
is seen at the front end, and the welding lines are clear.
The cross-section was quite uniform when it reached
steady state extrusion.
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