Deform Manual

DEFORM V11.
0 (PC) Documentation
Table of Contents
1 Introduction to DEFORM ............................................................................................................................ 3
1.1. Overview of DEFORM ....................................................................................................................... 4
1.2. DEFORM family of products .............................................................................................................. 7
1.2.1. BASE PRODUCTS .............................................................................................................. 8
1.2.2. SUPPORT MODULES ......................................................................................................... 9
1.2.3. ADD-ON Modules .............................................................................................................. 11
1.3. Capabilities ...................................................................................................................................... 14
1.3.1. Deformation ....................................................................................................................... 14
1.3.2. Heat Treatment .................................................................................................................. 15
1.4. Analyzing manufacturing processes with DEFORM ....................................................................... 19
1.5. Before you begin ............................................................................................................................. 22
1.6. The DEFORM system ..................................................................................................................... 24
1.6.1. Pre-processing ................................................................................................................... 24
1.6.2. Running the simulation ...................................................................................................... 25
1.6.3. Post-processor ................................................................................................................... 26
1.7. Geometry representation ................................................................................................................. 28
1.8. Creating input data .......................................................................................................................... 31
1.9. Units................................................................................................................................................. 34
1.10. File system ................................................................................................................................. 37
1.11. Release Notes - V11.0 (PC) ....................................................................................................... 40
2 Integrated Pre Processor ......................................................................................................................... 53
2.1. GUI Main and Pre-processor Layout ............................................................................................... 54
2.1.1. Integrated GUI Interference ............................................................................................... 54
2.1.1.1. File Menu.................................................................................................................... 57
2.1.1.2. Simulation Menu ........................................................................................................ 60
2.1.1.3. Tool Menu .................................................................................................................. 61
2.1.1.3.1. DB Manager ............................................................................................................... 61
2.1.1.4. View............................................................................................................................ 63
2.1.1.5. Options ....................................................................................................................... 64
2.1.1.6. Help ............................................................................................................................ 64
2.1.2. Pre-Processor Layout ........................................................................................................ 66
2.1.3. Graphic Utilities .................................................................................................................. 67
2.1.3.1. File.............................................................................................................................. 67
2.1.3.2. Input ........................................................................................................................... 69
2.1.3.2.1. Simulation controls ..................................................................................................... 69
2.1.3.2.2. Material ....................................................................................................................... 69
2.1.3.2.3. Object positioning ....................................................................................................... 69
2.1.3.2.4. Inter Object ................................................................................................................. 70
2.1.3.2.5. Database .................................................................................................................... 70
2.1.3.2.6. Convert 2D to 3D ........................................................................................................ 70
2.1.3.2.7. Object Node ................................................................................................................ 70
2.1.3.2.8. Object Elements ......................................................................................................... 70
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DEFORM V11.0 (PC) Documentation
2.1.3.2.9. Object Edges .............................................................................................................. 70

2.1.3.2.10. Boolean Operation............................................................................................ 71
2.1.3.2.11. Data Interpolation ............................................................................................. 71
2.1.3.3. Viewport ..................................................................................................................... 72
2.1.3.3.1. Refresh (F5) ............................................................................................................... 72
2.1.3.3.2. View Fit (F3) ............................................................................................................... 72
2.1.3.3.3. View back (F4) ........................................................................................................... 72
2.1.3.3.4. Auto Fit ....................................................................................................................... 72
2.1.3.3.5. Load and Save ........................................................................................................... 72
2.1.3.4. Display........................................................................................................................ 74
2.1.3.4.1. Measure ...................................................................................................................... 74
2.1.3.4.2. Select .......................................................................................................................... 75
2.1.3.4.3. Pan (Shift+LMB) ........................................................................................................ 75
2.1.3.4.4. Dynamic zoom (Alt+LMB) .......................................................................................... 75
2.1.3.4.5. Box Zoom Window (Ctrl+Alt+LMB) ........................................................................... 75
2.1.3.4.6. Rotate (Ctrl+LMB)...................................................................................................... 76
2.1.3.4.7. Rotate X ...................................................................................................................... 76
2.1.3.4.8. Rotate Y ...................................................................................................................... 76
2.1.3.4.9. Rotate Z ...................................................................................................................... 76
2.1.3.4.10. Isometric View .................................................................................................. 76
2.1.3.4.11. Viewpoint .......................................................................................................... 76
2.1.3.4.12. Screen Upward ................................................................................................. 77
2.1.3.4.13. Show Model ...................................................................................................... 77
2.1.3.5. Model.......................................................................................................................... 78
2.1.3.6. Tools........................................................................................................................... 78
2.1.3.7. View............................................................................................................................ 79
2.1.3.8. Options ....................................................................................................................... 79
2.1.3.8.1. Environment ............................................................................................................... 79
2.1.3.8.2. Preferences ................................................................................................................ 88
2.1.3.8.3. Display properties ....................................................................................................... 91
2.1.3.8.4. Graph properties ......................................................................................................... 92
2.1.3.8.5. Save current settings .................................................................................................. 92
2.1.3.9. Help: ........................................................................................................................... 93
2.1.3.10. Axis Tools: ..................................................................................................................... 93
2.1.4. Object Display Modes ........................................................................................................ 94
2.1.5. Right Mouse Button Display Options ................................................................................. 94
2.1.5.1. Show Dimensions [2D, 3D] ........................................................................................ 95
2.1.5.2. Show Origin Axis [2D, 3D].......................................................................................... 95
2.1.5.3. Show Step Info. [2D, 3D]............................................................................................ 95
2.1.5.4. Show Ruler [2D] ......................................................................................................... 96
2.1.5.5. Show Current Object mark [2D, 3D] .......................................................................... 96
2.1.5.6. Contact Display [2D, 3D] ............................................................................................ 96
2.1.5.7. Calculate Contact Area [3D] ...................................................................................... 97
2.1.5.8. Use Object Coordinate for rotation [3D]: .................................................................... 97
2.1.5.9. Measure [2D, 3D] ....................................................................................................... 97
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Table of Contents
2.1.5.10. Picking mode [2D, 3D] .................................................................................................. 97

2.1.5.11. Picking Sensitivity [2D, 3D] ........................................................................................... 98
2.1.5.12. Theme [2D, 3D] ............................................................................................................. 98
2.1.5.13. Set as Default [2D, 3D] ................................................................................................. 99
2.1.5.14. Change feature angle [3D] ............................................................................................ 99
2.1.5.15. Viewport information [2D, 3D] ..................................................................................... 100
2.1.5.16. Display Properties [2D, 3D] ......................................................................................... 101
2.2. Simulation Controls ....................................................................................................................... 103
2.2.1. Main controls ................................................................................................................... 104
2.2.1.1. Simulation Information ............................................................................................. 104
2.2.1.1.1. Simulation title (TITLE) [2D, 3D] ............................................................................... 104
2.2.1.1.2. Operation name (SIMNAM) [2D, 3D] ........................................................................ 104
2.2.1.1.3. Operation number (CURSIM) [2D, 3D] ..................................................................... 105
2.2.1.1.4. Mesh number (MESHNO) [2D, 3D] .......................................................................... 105
2.2.1.1.5. Geometry type (GEOTYP) [2D] ................................................................................ 105
2.2.1.2. Units (UNIT) [2D, 3D] ............................................................................................... 106
2.2.1.3. Type (STYPE) .......................................................................................................... 106
2.2.1.3.1. Lagrangian Incremental [2D, 3D] ............................................................................. 107
2.2.1.3.2. ALE Rolling [3D] ....................................................................................................... 107
2.2.1.3.3. Steady-State machining [2D, 3D] ............................................................................. 107
2.2.1.3.4. Ring Rolling [3D] ....................................................................................................... 107
2.2.1.3.5. Steady-State extrusion [3D]...................................................................................... 108
2.2.1.3.6. ALE Extrusion [3D] ................................................................................................... 108
2.2.1.4. Simulation modes (SMODE, TRANS) ...................................................................... 108
2.2.1.4.1. Heat transfer ............................................................................................................. 108
2.2.1.4.2. Deformation .............................................................................................................. 108
2.2.1.4.3. Transformation ......................................................................................................... 108
2.2.1.4.4. Diffusion .................................................................................................................... 108
2.2.1.4.5. Grain ......................................................................................................................... 108
2.2.1.4.6. Heating ..................................................................................................................... 109
2.2.2. Simulation steps .............................................................................................................. 110
2.2.2.1. Starting step number (NSTART) [2D, 3D]................................................................ 110
2.2.2.2. Number of simulation steps (NSTEP) [2D, 3D] ....................................................... 111
2.2.2.3. Step increment to save (STPINC) [2D, 3D] ............................................................ 111
2.2.2.4. Primary die (PDIE) [2D, 3D] ..................................................................................... 111
2.2.3. Step Increment ................................................................................................................ 112
2.2.3.1. Step increment control (DSMAX/DTMAX) [2D, 3D] ................................................. 113
2.2.3.2. Step definition (STPDEF) [2D, 3D] .......................................................................... 113
2.2.3.3. Selecting time step and number of steps [2D, 3D] .................................................. 113
2.2.3.4. Sub-stepping Controls.............................................................................................. 114
2.2.3.4.1. Strain per step (DEMAX) [2D, 3D] ............................................................................ 114
2.2.3.4.2. Contact Time (DTSUB) [2D, 3D] .............................................................................. 114
2.2.3.4.3. Polygon length sub step (DPLEN) [3D] .................................................................... 115
2.2.4. Advanced Step Controls .................................................................................................. 116
2.2.4.1. Temperature change per step (DTPMAX) [2D, 3D] ................................................. 117
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2.2.4.2. Deformation time per step (DTPMAX) [2D].............................................................. 117

2.2.4.3. Maximum Sliding Error ............................................................................................. 117
2.2.4.4. Volume change per step (DVMAX) [2D] .................................................................. 118
2.2.5. Stopping Controls ............................................................................................................ 119
2.2.5.1. Process Duration (TMAX) [2D, 3D] ......................................................................... 119
2.2.5.2. Primary Die Displacement (SMAX) [2D, 3D]........................................................... 119
2.2.5.3. Minimum velocity of Primary Die (VMIN) [2D, 3D] .................................................. 120
2.2.5.4. Maximum load of Primary Die (LMAX) [2D, 3D] ...................................................... 120
2.2.5.5. Maximum strain in any Element (EMAX) [2D, 3D] ................................................... 120
2.2.5.6. Stopping distance (MDSOBJ) [2D, 3D] .................................................................... 120
2.2.5.7. Stopping Plane (REFPOS) [2D, 3D] ........................................................................ 121
2.2.5.8. Temperature stopping control [2D, 3D] .................................................................... 122
2.2.6. Remesh Criteria ............................................................................................................... 123
2.2.7. Iteration Controls ............................................................................................................. 124
2.2.7.1. Deformation solver (SOLMTD) [2D, 3D] .................................................................. 125
2.2.7.1.1. Sparse [2D] ............................................................................................................... 125
2.2.7.1.2. Skyline [2D] .............................................................................................................. 125
2.2.7.1.3. Conjugate Gradient [3D] ........................................................................................... 125
2.2.7.2. Iteration methods (ITRMTH) [2D, 3D] ...................................................................... 129
2.2.7.2.1. Newton-Raphson ...................................................................................................... 129
2.2.7.2.2. Direct ........................................................................................................................ 130
2.2.7.3. Convergence error limits (CVGERR) [2D, 3D] ......................................................... 130
2.2.7.4. Temperature solver (SOLMTT) [2D, 3D]................................................................. 130
2.2.7.4.1. Sparse [2D] ............................................................................................................... 130
2.2.7.4.2. Skyline [2D] .............................................................................................................. 130
2.2.7.5. Maximum number of iterations (ITRMXD, ITRMXT) [2D, 3D] .................................. 132
2.2.7.6. Bandwidth optimization (DEFBWD, TMPBWD) [2D, 3D] ......................................... 132
2.2.8. Processing Conditions ..................................................................................................... 133
2.2.8.1. Heat Transfer [2D, 3D] ............................................................................................ 133
2.2.8.1.1. Environment temperature (ENVTMP) ...................................................................... 133
2.2.8.1.2. Radiation................................................................................................................... 134
2.2.8.1.3. Convection coefficient (CNVCOF) ............................................................................ 134
2.2.8.2. Diffusion [2D, 3D] ..................................................................................................... 134
2.2.8.2.1. Environment atom content (ENVATM) [MIC] ........................................................... 134
2.2.8.2.2. Reaction rate coefficient (ACVCOF) [DIF] ................................................................ 135
2.2.8.3. Induction [2D, 3D] .................................................................................................... 135
2.2.8.3.1. Magnetic permeability (ENVMPR) ............................................................................ 135
2.2.8.3.2. Magnetic permittivity (ENVMPT) .............................................................................. 135
2.2.8.3.3. Source Energy Ratio (EHRATE) .............................................................................. 136
2.2.8.4. Constants [2D, 3D] ................................................................................................... 136
2.2.8.4.1. Interface penalty constant (PENINF) ........................................................................ 136
2.2.8.4.2. Mechanical to heat conversion (UNTE2H) ............................................................... 137
2.2.8.4.3. Time integration factor (TINTGF) ............................................................................. 137
2.2.8.4.4. Boltzmann constant (BLZMAN) ................................................................................ 137
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Table of Contents
2.2.9. Advanced Controls .......................................................................................................... 138

2.2.9.1. Variables [2D, 3D] .................................................................................................... 138
2.2.9.1.1. Current Global Time/Current Local Time (TNOW) ................................................... 138
2.2.9.1.2. Primary Workpiece (PDIE) ....................................................................................... 139
2.2.9.1.3. Use original additive rule for transformation kinetics (TRANS) ................................ 139
2.2.9.2. Error Tolerances [2D, 3D] ........................................................................................ 139
2.2.9.2.1. Contact release method (CNTERR) [2D] ................................................................. 139
2.2.9.2.2. Geometry error (GEOERR) [2D, 3D] ........................................................................ 139
2.2.9.3. User defined variables (USRDEF) [2D, 3D] ............................................................. 141
2.2.9.4. Output Control [2D, 3D]............................................................................................ 141
2.2.9.5. Nodal Oscillations [2D] ............................................................................................. 144
2.2.9.5.1. Corner oscillations .................................................................................................... 145
2.2.9.5.2. Repeated touching / separating ............................................................................... 145
2.2.10. Control Files ......................................................................................................................... 146
2.2.10.1. Category 1 ................................................................................................................... 147
2.2.10.1.1. Double corner constraints .............................................................................. 147
2.2.10.1.2. Solver switch control....................................................................................... 147
2.2.10.2. Category 2 ................................................................................................................... 147
2.2.10.2.1. Additional remeshing criteria .......................................................................... 148
2.2.10.2.2. Body weight .................................................................................................... 148
2.2.11. Post processing Variable ..................................................................................................... 149
2.3. Material Data ................................................................................................................................. 152
2.3.1. Phases and mixtures (MSTMTR) [MIC] ........................................................................... 153
2.3.2. Plastic Data ...................................................................................................................... 158
2.3.2.1. Flow Stress (FSTRES) ............................................................................................. 158
2.3.2.1.1. Tabular data format .................................................................................................. 159
2.3.2.1.2. Power Law ................................................................................................................ 159
2.3.2.1.3. Flow stress for aluminum alloys (Type 1) ................................................................. 160
2.3.2.1.5. Linear hardening ....................................................................................................... 160
2.3.2.1.6. Generalized Johnson and Cook model .................................................................... 161
2.3.2.1.7. Zerilli-Armstrong model ............................................................................................ 161
2.3.2.1.8. Norton-Hoff Law model............................................................................................. 162
2.3.2.1.9. Microstructure Flow stress model based on dislocation density and burgers vector162
2.3.2.1.10. f(strn,strnrt,O,T): (This option available only in MO) ...................................... 163
2.3.2.1.11. Tabulate Data: (This option available only in MO) ......................................... 165
2.3.2.1.12. Tabulate Data (LOG): (This option available only in MO) .............................. 166
2.3.2.1.13. Bird-Mukharjee-Dorn equation: (This option available only in MO) ............... 166
2.3.2.1.14. User defined flow stress routine ..................................................................... 167
2.3.2.2. Creep (CREEP) [MIC] .............................................................................................. 171
2.3.2.2.1. Perzyna's model ....................................................................................................... 173
2.3.2.2.2. Power Law ................................................................................................................ 174
2.3.2.2.3. Baily-Norton's model................................................................................................. 174
2.3.2.2.4. Soderburg's model.................................................................................................... 174
2.3.2.2.5. Tabular data ............................................................................................................. 175
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2.3.2.2.6. User Routines ........................................................................................................... 177

2.3.2.3. Yield function type .................................................................................................... 178
2.3.2.3.1. Von Mises ................................................................................................................. 179
2.3.2.3.2. Hill’s quadratic (FGHLMN)........................................................................................ 179
2.3.2.3.3. Hill’s quadratic (R value)........................................................................................... 180
2.3.2.3.4. Lankford coefficient (R value) ................................................................................... 180
2.3.2.3.5. Hill’s Quadratic (polycrystalline plasticity model)...................................................... 181
2.3.2.3.6. User’s routine ........................................................................................................... 182
2.3.2.4. Hardening model (HDNRUL) [MIC] .......................................................................... 182
2.3.3. Elastic data ...................................................................................................................... 183
2.3.3.1. Young's modulus (YOUNG) ..................................................................................... 183
2.3.3.2. Poisson's ratio (POISON) ........................................................................................ 184
2.3.3.3. Thermal expansion (EXPAND) ................................................................................ 184
2.3.3.4. Material Reference Temperature (REFTMP) ........................................................... 185
2.3.4. Thermal data .................................................................................................................... 185
2.3.4.1. Thermal conductivity (THRCND) ............................................................................. 186
2.3.4.2. Heat capacity (HEATCP) ......................................................................................... 186
2.3.4.3. Emissivity (EMSVTY) ............................................................................................... 187
2.3.4.4. Density (DENSTY) ................................................................................................... 187
2.3.5. Diffusion data ................................................................................................................... 187
2.3.5.1. Diffusion coefficient (DIFCOE) ................................................................................. 188
2.3.6. Grain growth/recrystallization model ............................................................................... 190
2.3.6.1. Avrami Model: .......................................................................................................... 191
2.3.6.1.1. Dynamic Recrystallization ........................................................................................ 192
2.3.6.1.2. Static Recrystallization ............................................................................................. 193
2.3.6.1.3. Meta-dynamic Recrystallization ................................................................................ 194
2.3.6.1.4. Grain Growth ............................................................................................................ 194
2.3.6.2. Mesoscale Model ..................................................................................................... 196
2.3.7. Hardness data [MIC] ........................................................................................................ 197
2.3.7.1. Hardness of each phase (HDNPHA) ....................................................................... 198
2.3.7.2. Jominy curve (JOMINY) ........................................................................................... 198
2.3.7.3. Cooling time (HDNTIM) ............................................................................................ 198
2.3.8. Electromagnetic data ....................................................................................................... 199
2.3.9. Advanced Features .......................................................................................................... 199
2.3.9.1. Fracture Data (FRCMOD) ........................................................................................ 200
2.3.9.1.1. Normalized C&L damage model .............................................................................. 201
2.3.9.1.2. Cockroft & Latham damage model ........................................................................... 201
2.3.9.1.3. McClintock damage model ....................................................................................... 201
2.3.9.1.4. Freudenthal damage model ..................................................................................... 201
2.3.9.1.5. Rice & Tracy damage model .................................................................................... 201
2.3.9.1.6. Oyane damage model .............................................................................................. 202
2.3.9.1.7. Oyane (negative) damage model ............................................................................. 202
2.3.9.1.8. Ayada damage model............................................................................................... 202
2.3.9.1.9. Ayada (negative) damage model ............................................................................. 202
2.3.9.1.10. Osakada damage model ................................................................................ 202
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2.3.9.1.11. Brozzo damage model.................................................................................... 203

2.3.9.1.12. Zhoa & Kuhn damage model .......................................................................... 203
2.3.9.1.13. Damage based on Maximum principal stress / ultimate tensile strength ....... 203
2.3.9.1.14. Damage user routine ...................................................................................... 203
2.3.9.1.15. Void Closure: (Option available only in MO) .................................................. 204
2.3.9.1.16. FLD : (Option available only in MO) ............................................................... 205
2.3.9.2. Mechanical Work to Heat (FRAE2H) ....................................................................... 206
2.3.9.3. Force per unit volume or Body Force (FPERV) ....................................................... 207
2.3.9.4. Centrifugal force ....................................................................................................... 207
2.3.9.5. Diffusion Bonding [Available only in MO] ................................................................. 207
2.3.9.6. Size Model (SIZESH and SIZEMD) ......................................................................... 210
2.3.9.7. Sintering Driving Force model [Available only in MO] .............................................. 212
2.3.9.7.1. Simple Elastic one-step ............................................................................................ 212
2.3.9.7.2. Skorohod .................................................................................................................. 213
2.3.9.7.3. Cocks ........................................................................................................................ 214
2.3.9.7.4. Shinagawa ................................................................................................................ 215
2.3.9.7.5. Ashby ........................................................................................................................ 215
2.3.9.7.6. Raj/Ashby ................................................................................................................. 216
2.3.10. Dislocation ........................................................................................................................... 217
2.3.11. Texture ................................................................................................................................. 217
2.3.12. Material data requirements .................................................................................................. 217
2.4. Inter Material Data ......................................................................................................................... 222
2.4.1. Transformation relation (PHASTF) [MIC] ........................................................................ 222
2.4.2. Kinetics model (TTTD) [MIC] ........................................................................................... 224
2.4.2.1. Diffusion type TTT table form (Temp, Stress, Atom) ............................................... 225
2.4.2.2. Martensitic type (Tms, Tms50 Table form) .............................................................. 226
2.4.2.3. Diffusion type (function) ........................................................................................... 227
2.4.2.4. Diffusion type (function and table) ........................................................................... 229
2.4.2.5. Martensitic type (function) ........................................................................................ 230
2.4.2.6. Diffusion type (simplified) ......................................................................................... 231
2.4.2.7. MEDC ....................................................................................................................... 232
2.4.2.8. Secondary alpha lath ............................................................................................... 234
2.4.2.9. Ti-beta to grain boundary alpha ............................................................................... 236
2.4.2.10. Ti-beta to side plate alpha ........................................................................................... 238
2.4.2.11. User routine ................................................................................................................. 240
2.4.3. Latent heat (PHASLH) [MIC] ........................................................................................... 241
2.4.4. Transformation induced volume change (PHASVL) [MIC] .............................................. 242
2.4.5. Transformation plasticity (TRNSFP) [MIC] ...................................................................... 243
2.4.6. Other ................................................................................................................................ 245
2.4.6.1. Thermal Direction ..................................................................................................... 245
2.4.6.2. Equilibrium volume fraction ...................................................................................... 246
2.4.6.3. Variation selection model (option available only in MO): ......................................... 246
2.4.6.4. Interface Energy (option available only in MO): ....................................................... 246
2.4.7. Coarsening....................................................................................................................... 246
2.5. Object General Definition .............................................................................................................. 248
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2.5.1. Adding, deleting objects................................................................................................... 249

2.5.2. Object name (OBJNAM) .................................................................................................. 249
2.5.3. Primary Die (PDIE) .......................................................................................................... 251
2.5.4. Object type (OBJTYP) ..................................................................................................... 251
2.5.4.1. Rigid [2D, 3D] ........................................................................................................... 251
2.5.4.2. Elastic [2D, 3D] ........................................................................................................ 251
2.5.4.3. Plastic [2D, 3D] ........................................................................................................ 252
2.5.4.4. Elasto-plastic (Ela-Pla) [2D, 3D] .............................................................................. 252
2.5.4.5. Porous [2D, 3D] ........................................................................................................ 253
2.5.4.6. User [2D] .................................................................................................................. 253
2.5.5. Object material ................................................................................................................. 255
2.5.6. Object initial conditions .................................................................................................... 255
2.6. Geometry Data .............................................................................................................................. 258
2.6.1. 2D Geometry Data Definition ........................................................................................... 258
2.6.1.1. Geometry Rules for 2D ............................................................................................ 259
2.6.1.2. 2D Geometry Tools .................................................................................................. 260
2.6.1.2.1. Importing Geometry [2D] .......................................................................................... 260
2.6.1.2.2. Scale Geometry [2D] ................................................................................................ 260
2.6.1.2.3. Check Geometry [2D] ............................................................................................... 261
2.6.1.2.4. Reverse geometry [2D]............................................................................................. 262
2.6.1.2.5. Edit Boundary [2D] ................................................................................................... 262
2.6.1.2.6. Extract Border [2D] ................................................................................................... 264
2.6.1.2.7. Extract Mesh [2D] ..................................................................................................... 264
2.6.1.2.8. Primitives [2D] .......................................................................................................... 264
Show geometry inside mark [2D]................................................................................................ 268
2.6.1.3. 2D Geometry Editing ................................................................................................ 269
2.6.1.3.1. Creating geometries [2D].......................................................................................... 271
2.6.1.3.2. Multiple boundaries [2D] ........................................................................................... 271
2.6.1.3.3. Geometry formats [2D] ............................................................................................. 271
2.6.1.4. 2D Topology ............................................................................................................. 274
2.6.1.5. Construct Geometry [2D] ......................................................................................... 279
2.6.1.6. 2D Geometry Options .............................................................................................. 279
2.6.2.1. Geometry rules for 3D .............................................................................................. 282
2.6.2.2. 3D Geometry Tools .................................................................................................. 284
2.6.2.2.1. Import Geometry [3D] ............................................................................................... 284
2.6.2.2.2. Check Geometry [3D] ............................................................................................... 287
2.6.2.2.4. Scale Geometry [3D] ................................................................................................ 288
2.6.2.2.5. Check Interception [3D] ............................................................................................ 288
2.6.2.2.6. Show /hide normal [3D] ............................................................................................ 288
2.6.2.2.7. Find Axis [3D] ........................................................................................................... 288
2.6.2.2.8. Fix geometry [3D] ..................................................................................................... 288
2.6.2.2.9. Stitch geometry [3D] ................................................................................................. 289
2.6.2.2.10. Extract Border [3D] ......................................................................................... 289
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Table of Contents
2.6.2.2.11. Extract Mesh [3D] ........................................................................................... 289

2.6.2.2.12. Geometry Primitives [3D]................................................................................ 289
2.6.2.3. Examine 3D Geometry ............................................................................................. 295
2.6.2.4. Symmetric Surface [3D] ........................................................................................... 296
2.6.2.5. 3D Geometric polygon deletion ................................................................................ 299
2.7. Mesh Data Definition ..................................................................................................................... 302
2.7.1. 2D Mesh Data Definition .................................................................................................. 302
2.7.1.1. 2D Mesh Tools ......................................................................................................... 302
2.7.1.1.1. Import Mesh [2D] ...................................................................................................... 303
2.7.1.1.2. Number of Elements [2D] ......................................................................................... 303
2.7.1.1.3. Generate Mesh [2D] ................................................................................................. 303
2.7.1.1.4. Check Mesh [2D] ...................................................................................................... 303
2.7.1.1.5. Area and Volume [2D] .............................................................................................. 303
2.7.1.1.6. Manual Remesh [2D] ................................................................................................ 304
2.7.1.2. 2D Mesh Detailed Settings....................................................................................... 306
2.7.1.2.1. System Setup ........................................................................................................... 307
2.7.1.2.2. User-Defined MESH [2D] ......................................................................................... 318
2.7.1.3. 2D Remeshing criteria.............................................................................................. 320
2.7.1.3.1. Maximum interference depth (RMDPTH) [2D, 3D] ................................................... 321
2.7.1.3.2. Maximum stroke increment (RMSTRK) [2D, 3D] ..................................................... 321
2.7.1.3.3. Maximum time increment (RMTIME) [2D, 3D] ......................................................... 321
2.7.1.3.4. Maximum step increment (RMSTEP) [2D, 3D]......................................................... 321
2.7.2.1. 3D Mesh Tools ......................................................................................................... 323
2.7.2.1.1. Import Mesh [3D] ...................................................................................................... 323
2.7.2.1.3. Finer internal mesh [3D] ........................................................................................... 324
2.7.2.1.4. Manual Remesh [3D] ................................................................................................ 324
2.7.2.2.1. System Setup ........................................................................................................... 328
2.7.2.2.2. User-Defined Mesh Settings [3D] ............................................................................. 337
2.7.2.3.1. General Remesh criteria [3D] ................................................................................... 340
2.7.2.3.2. Remeshing Method [3D] ........................................................................................... 341
2.8. Movement Controls Definition ....................................................................................................... 344
2.8.1. Translational Movement .................................................................................................. 346
2.8.1.1. Speed control ........................................................................................................... 346
2.8.1.2. Force control ............................................................................................................ 349
2.8.1.3. Hammer Energy ....................................................................................................... 351
2.8.1.3.1. Anvil Type Hammer [2D, 3D] .................................................................................... 353
2.8.1.3.2. Counterblow Hammer [2D, 3D] ................................................................................ 355
2.8.1.4. Screw press ............................................................................................................. 357
2.8.1.5. Tools Option ............................................................................................................. 360
2.8.1.5.1. Hammer/Screw Multiple operation [2D, 3D] ............................................................. 360
xi
2.8.1.5.2. Rolling Multiple operation [2D] ................................................................................. 364

2.8.1.6. Mechanical press ..................................................................................................... 368
2.8.1.6.1. Crank Press [2D, 3D] ................................................................................................ 368
2.8.1.6.2. Knuckle or Wedge Press [2D, 3D] ............................................................................ 372
2.8.1.6.3. Secondary Control (s)............................................................................................... 374
2.8.1.6.4. Elastic Losses ........................................................................................................... 375
2.8.1.7. Hydraulic press ........................................................................................................ 377
2.8.1.7.1. Speed [2D, 3D] ......................................................................................................... 377
2.8.1.7.2. Average strain rate [2D, 3D] ..................................................................................... 378
2.8.1.8. Sliding Die Movement .............................................................................................. 380
2.8.1.9. Path Movement Controls.......................................................................................... 383
2.8.1.9.1. Local and Global Co-ordinates [3D] ......................................................................... 385
2.8.1.9.2. Align Rotation center to object center [2D, 3D] ........................................................ 387
2.8.1.9.3. Synchronize with the defined path data [2D, 3D] ..................................................... 388
2.8.2. Rotational movement ....................................................................................................... 391
2.8.2.1. Controlling Method ................................................................................................... 393
2.8.2.1.1. Torque ...................................................................................................................... 393
2.8.2.1.2. Angular Velocity ........................................................................................................ 394
2.8.3. Torsional movement ........................................................................................................ 395
2.8.3.1.1. Torque ...................................................................................................................... 397
2.8.3.1.3. Energy ...................................................................................................................... 398
2.8.4. Assigning movement to Deformable objects ................................................................... 399
2.8.5. Movement Preview .......................................................................................................... 401
2.8.6. Movement control user subroutines ................................................................................ 403
2.9. Boundary Conditions ..................................................................................................................... 406
2.9.1. Deformation boundary conditions .................................................................................... 410
2.9.1.1. Velocity BCC [2D, 3D] .............................................................................................. 410
2.9.1.2. Free Distortion BCC [ 3D] ........................................................................................ 411
2.9.1.3. Force BCC [2D, 3D] ................................................................................................. 415
2.9.1.4. Pressure BCC [2D, 3D] ............................................................................................ 419
2.9.1.5. Displacement and shrink fit BCC [2D, 3D] ............................................................... 421
2.9.1.6. Movement BCC [2D, 3D].......................................................................................... 421
2.9.1.7. Contact [2D, 3D] ....................................................................................................... 421
2.9.1.8. Symmetry BCC [3D]: ................................................................................................ 422
2.9.1.9. Beginning surface BCC [3D] .................................................................................... 422
2.9.1.10. Free Surface BCC [3D] ............................................................................................... 422
2.9.1.11. Advanced deformation BCC [2D, 3D] ......................................................................... 423
2.9.1.12. Rigid Super Element Window [MO - 3D] ..................................................................... 424
2.9.2. Thermal Boundary Conditions ......................................................................................... 425
2.9.2.1. Heat exchange with the environment BCC [2D/3D] ................................................. 425
2.9.2.2. Temperature BCC [2D, 3D] ...................................................................................... 426
2.9.2.3. Heat flux BCC [2D/3D] ............................................................................................. 426
2.9.2.4. Nodal heat BCC [2D, 3D] ......................................................................................... 426
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2.9.2.5. Advanced Thermal BCC [2D, 3D] ........................................................................... 427

2.9.3. Diffusion Boundary Conditions [DIF] ............................................................................... 427
2.9.3.1. Diffusion with the environment BCC [2D/3D] ........................................................... 427
2.9.3.2. Fixed atom content BCC [2D/3D] ............................................................................. 428
2.9.3.3. Atom flux BCC [2D/3D] ............................................................................................ 428
2.9.3.4. Advanced Diffusion BCC [2D/3D] ............................................................................ 428
2.9.4. Heating Boundary Conditions .......................................................................................... 429
2.9.4.1. Resistance Heating [2D, 3D] .................................................................................... 429
2.9.4.1.1. Voltage BCC ............................................................................................................. 429
2.9.4.1.2. Current Flux BCC ..................................................................................................... 429
2.9.4.2. Induction Heating (BEM) .......................................................................................... 429
2.9.4.2.1. Heating Surface[2D, 3D]........................................................................................... 429
2.9.4.2.2. Coil Begin surface [3D] ............................................................................................. 429
2.9.4.2.3. Coil End surface [3D] ................................................................................................ 429
2.9.4.3. Induction Heating ..................................................................................................... 430
2.10. Object Properties ...................................................................................................................... 432
2.10.1. Deformation properties ........................................................................................................ 434
2.10.1.1. Target Volume (TRGVOL) [2D, 3D] ............................................................................ 435
2.10.1.2. Volume penalty constant (PENVOL) [2D, 3D] ............................................................ 436
2.10.1.3. Average strain rate (AVGSTR) [2D, 3D] ..................................................................... 436
2.10.1.4. Limiting strain rate (LMTSTR) [2D, 3D] ....................................................................... 436
2.10.1.5. Generalized plane strain control (ZSTR) [2D] ............................................................. 437
2.10.1.6. Elasto-plastic initial guess (ELPSOL) [2D, 3D] ........................................................... 438
2.10.1.7. Creep solutions (CREEP) [MIC] [2D, 3D] ................................................................... 438
2.10.2. Thermal properties ............................................................................................................... 439
2.10.2.1. Reference temperature (REFTMP) [2D, 3D]............................................................... 439
2.10.2.2. Truncation temperature (TMPLMT) [2D, 3D] .............................................................. 440
2.10.2.3. Stopping temperature (OTPRNG) [2D, 3D] ................................................................ 440
2.10.3. Fracture properties .............................................................................................................. 441
2.10.3.1. Fracture step (FRCSTP) [2D]...................................................................................... 442
2.10.3.2. Fracture elements (FRCNEL) [2D, 3D] ....................................................................... 442
2.10.4. Hardness properties [MIC] ................................................................................................... 443
2.10.5. Induction Heating ................................................................................................................. 444
2.10.5.1. Current frequency [2D, 3D] ......................................................................................... 445
2.10.5.2. Volume Charge [2D, 3D] ............................................................................................. 445
2.10.5.3. Data Definition [2D, 3D] .............................................................................................. 445
2.10.6. Rotational Symmetry ........................................................................................................... 446
2.10.7. Body Force........................................................................................................................... 448
2.10.8. User (USRSUB) ................................................................................................................... 449
2.10.9. Reference [MO] ................................................................................................................... 449
2.10.10. RSE [MO] ..................................................................................................................... 450
2.11. Advanced Object Data Definition ............................................................................................. 453
2.11.1. Object node variables .......................................................................................................... 455
2.11.1.1. Deformation ................................................................................................................. 460
2.11.1.1.1. General ........................................................................................................... 460
xiii
2.11.1.1.2. Stress(Nodal) .................................................................................................. 461

2.11.1.2. Thermal ....................................................................................................................... 464
2.11.1.2.1. Node Temperature (NDTMP) ......................................................................... 464
2.11.1.2.2. Heat (NDHEAT) .............................................................................................. 464
2.11.1.2.3. Heat flux (NDFLUX)........................................................................................ 465
2.11.1.2.4. Boundary condition code (BCCTMP) ............................................................. 465
2.11.1.2.5. Boundary condition function (BCCTFN) ......................................................... 465
2.11.1.3. Diffusion [DIF] ............................................................................................................. 466
2.11.1.3.1. Atom Percentage (DATOM) ........................................................................... 466
2.11.1.3.2. Diffusion Flux (CRBFLX) ................................................................................ 466
2.11.1.3.3. Diffusion BCC (BCCCRB) .............................................................................. 467
2.11.1.4. Electric Heating ........................................................................................................... 468
2.11.1.4.1. Electric field intensity (VOTAGE) ................................................................... 468
2.11.1.4.2. Resistance BCC (BCCRHT) ........................................................................... 469
2.11.1.4.3. Current Flux (RHTFLX) .................................................................................. 469
2.11.1.5. User ............................................................................................................................. 469
2.11.2. Object element variables ..................................................................................................... 471
2.11.2.1. Deformation ................................................................................................................. 473
2.11.2.1.1. General ........................................................................................................... 473
2.11.2.1.2. Stress components (STRESS) ....................................................................... 473
2.11.2.1.3. Back Stress Components (YLDS) [MIC] ........................................................ 474
2.11.2.1.4. Strain Rate ...................................................................................................... 474
2.11.2.1.5. Mat. Angle (MATAXI)...................................................................................... 474
2.11.2.2. Hardness [MIC] ........................................................................................................... 475
2.11.2.2.1. Hardness (HDNOBJ1) .................................................................................... 475
2.11.2.2.2. Cooling Time (HDNOBJ2) .............................................................................. 476
2.11.2.3.1. Electric field intensity R .................................................................................. 477
2.11.2.4. User ............................................................................................................................. 478
2.11.2.5. Microstructure ............................................................................................................. 479
2.11.2.5.1. Grain ............................................................................................................... 479
2.11.2.5.2. Phase (Transformation) .................................................................................. 479
2.11.2.5.3. Size ................................................................................................................. 481
2.11.2.5.4. Texture ........................................................................................................... 481
2.11.3. Boolean Operation ............................................................................................................... 482
2.11.4. Data Interpolation ................................................................................................................ 487
2.11.5. Slicing .................................................................................................................................. 489
2.11.6. Object edge variables .......................................................................................................... 490
2.11.6.1. Deformation ................................................................................................................. 491
2.11.6.1.1. Deform BCC (ECCDEF) ................................................................................. 491
2.11.6.1.2. Function BCC (ECDEFN) ............................................................................... 491
2.11.6.1.3. Pressure (ECPRES) ....................................................................................... 491
2.11.6.2. Thermal ....................................................................................................................... 491
2.11.6.2.1. Node Temperature (ECCTMP) ....................................................................... 492
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Table of Contents
2.11.6.2.2. Flux (ECHFLX) ............................................................................................... 492

2.11.6.3. Diffusion ...................................................................................................................... 492
2.11.6.3.1. Diffusion (ECCATM) ....................................................................................... 492
2.11.6.3.2. Function BCC (ECATFN) ............................................................................... 492
2.11.6.3.3. Diffusion Flux (ECAFLX) ................................................................................ 492
2.11.6.4.1. Heating BCC (ECCRHT) ................................................................................ 493
2.11.6.4.2. Function BCC (ECRHFN) ............................................................................... 493
2.11.6.4.3. Current Flux (ECRFLX) .................................................................................. 493
2.11.7. Mirror Merge: ....................................................................................................................... 494
2.12. Object Positioning..................................................................................................................... 497
2.12.1. Drag ..................................................................................................................................... 497
2.12.2. Offset Positioning ................................................................................................................. 499
2.12.2.1. Centroid Positioning .................................................................................................... 500
2.12.3. Interference positioning ....................................................................................................... 501
2.12.4. Rotational positioning .......................................................................................................... 503
2.12.5. Drop positioning ................................................................................................................... 506
2.12.6. Flip ....................................................................................................................................... 508
2.12.7. Coupled positioning ............................................................................................................. 510
2.13. Inter-object Data Definition ....................................................................................................... 513
2.13.1. Contact relation (CNTACT).................................................................................................. 516
2.13.2. Deformation inter-object definition ....................................................................................... 518
2.13.2.1. Friction (FRCFAC) [2D, 3D] ........................................................................................ 518
2.13.2.1.1. Constant Shear (sticking) [2D, 3D] ................................................................. 518
2.13.2.1.2. Coulomb (sliding) [2D, 3D] ............................................................................. 519
2.13.2.1.3. Hybrid [2D, 3D] ............................................................................................... 519
2.13.2.1.4. Tau (shear stress) [2D] ................................................................................... 520
2.13.2.2. Separation criteria (SEPRES) [2D, 3D] ....................................................................... 526
2.13.2.2.1. Non Separable (SEPRES) [3D] ...................................................................... 526
2.13.2.2.2. Separation Density (SEPDEN) [2D] ............................................................... 527
2.13.2.3. Self Contact [2D, 3D] .................................................................................................. 528
2.13.2.4. Contact Method [3D] ................................................................................................... 528
2.13.2.4.1. Penalty ............................................................................................................ 528
2.13.2.4.2. Conforming Coupling ...................................................................................... 529
2.13.3. Thermal inter-object definition ............................................................................................. 530
2.13.3.1. Interface heat transfer coefficient (IHTCOF) [2D, 3D] ................................................ 530
2.13.3.2. Relative rotation (FRCROT) [2D] ................................................................................ 530
2.13.4. Heating Inter-object definition .............................................................................................. 532
2.13.4.1. Resistance [2D, 3D] .................................................................................................... 532
2.13.5. Friction window (FRCWIN) definition ................................................................................... 533
2.13.6. Tool Wear Window .............................................................................................................. 535
2.13.6.1. Archard's model [2D, 3D] ............................................................................................ 535
2.13.6.2. Usui's model ................................................................................................................ 536
2.13.7. Rigid Contact ....................................................................................................................... 538
2.14. Database Generation ............................................................................................................... 540
xv
2.14.1. Data errors ........................................................................................................................... 541

2.14.2. Data warnings ...................................................................................................................... 541
2.14.3. The Benefits of Integrated DB ............................................................................................. 541
2.15. 2D to 3D Conversion ................................................................................................................ 544
2.15.1. Built-in Conversion module Introduction .............................................................................. 545
2.15.1.1. Procedure to convert objects from 2D to 3D ............................................................... 546
2.15.2. Advanced Geometry Options............................................................................................... 550
2.15.2.1. Extrude ........................................................................................................................ 550
2.15.2.2. Revolve ....................................................................................................................... 550
3 Running Simulations .............................................................................................................................. 553
3.1. Start, Stop and resume Simulation................................................................................................ 554
3.2. Interactive and batch modes using Run option ............................................................................. 559
3.2.1. Interactive Mode .............................................................................................................. 559
3.2.2. Batch Queue Mode .......................................................................................................... 559
3.2.3. Queuing Simulations ........................................................................................................ 559
3.2.3.1. Running Batch Queue Server and Simulation Server ............................................. 559
3.2.3.2. Computer configuration requirements...................................................................... 559
3.2.3.3. Batch Queue Server setup ...................................................................................... 560
3.2.3.4. Simulation Server setup .......................................................................................... 561
3.2.3.5. Run (Options) settings ............................................................................................. 562
3.2.3.5.1. Other Run options dialog features ............................................................................ 563
3.2.3.5.2. Job options ............................................................................................................... 564
3.2.3.5.3. Multiprocessor options .............................................................................................. 564
3.3. Simulation Graphics ...................................................................................................................... 567
3.4. Process Monitor............................................................................................................................. 570
3.4.1. Running jobs .................................................................................................................... 570
3.4.2. Queuing jobs .................................................................................................................... 571
3.5. Registering MPICH ....................................................................................................................... 574
3.5.1. Registering 64 bit 3D FEM engine in PC ........................................................................ 574
3.5.2. Running 64 bit 3D FEM engine in Linux/PC .................................................................... 574
3.6. Running simulations remotely ....................................................................................................... 577
3.7. E-mail the results ........................................................................................................................... 586
3.8. Trouble Shooting Simulation Running ........................................................................................... 589
3.8.1. Message file messages ................................................................................................... 589
3.8.2. Simulation aborted by user error or License related errors. ............................................ 589
3.8.3. Cannot remesh at a negative step ................................................................................... 590
3.8.4. Remeshing is highly recommended ................................................................................ 590
3.8.5. Negative Jacobian ........................................................................................................... 591
3.8.6. Solution does not converge ............................................................................................. 591
3.8.7. Stiffness matrix is non-positive definite ........................................................................... 594
3.8.8. Zero pivot ......................................................................................................................... 594
3.8.9. Extrapolation of data ........................................................................................................ 594
3.8.10. Bad Element Shape ............................................................................................................. 595
3.8.11. Inconsistent Step Number .................................................................................................. 595
4 Integrated Post Processor...................................................................................................................... 599
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Table of Contents
4.1. Post Processor Overview .............................................................................................................. 600

4.1.1. Post Processor layout ...................................................................................................... 601
4.1.1.1. Display Window........................................................................................................ 602
4.1.1.2. Graphic Utilities ........................................................................................................ 602
4.1.1.3. Object Tree .............................................................................................................. 602
4.1.1.4. Display Modification Window ................................................................................... 603
4.2. Graphical Display .......................................................................................................................... 605
4.2.1. Object Tree Options ......................................................................................................... 605
4.2.1.1. Object Display Modes [2D, 3D] ................................................................................ 605
4.2.1.2. Tree Levels and Functions [2D, 3D] ........................................................................ 606
4.2.1.2.1. Problem Data [2D, 3D] ............................................................................................. 606
4.2.1.2.2. Object Data [2D, 3D] ................................................................................................ 608
4.2.1.2.3. Additional Post Processing Functions [2D, 3D] ........................................................ 612
4.2.1.3. Object Control Bar [2D, 3D] ..................................................................................... 612
4.2.2. Display window options ................................................................................................... 614
4.2.2.1. RMB Options ............................................................................................................ 614
4.2.2.2. Multi-Viewports Options ........................................................................................... 615
4.2.2.3. Window Options ....................................................................................................... 615
4.3. Graphical Utilities ........................................................................................................................... 617
4.3.1. File Menu ......................................................................................................................... 617
4.3.2. Viewport Menu ................................................................................................................. 619
4.3.2.1. Multiple viewport control........................................................................................... 620
4.3.2.2. Link View Port .......................................................................................................... 620
4.3.2.3. Copy Viewport .......................................................................................................... 620
4.3.2.4. Refresh (F5) ............................................................................................................. 621
4.3.2.5. View Fit (F4) ............................................................................................................. 621
4.3.2.6. View back (F3) ......................................................................................................... 621
4.3.2.7. Load and Save ......................................................................................................... 621
4.3.3. Display Menu ................................................................................................................... 622
4.3.4. Model Menu ..................................................................................................................... 622
4.3.5. Step Tools ........................................................................................................................ 622
4.3.5.1. Steps list ................................................................................................................... 622
4.3.5.1.1. Style .......................................................................................................................... 623
4.3.5.1.2. Range ....................................................................................................................... 624
4.3.5.1.3. Type .......................................................................................................................... 624
4.3.5.1.4. Data Purging ............................................................................................................. 624
4.3.5.2. Step Manipulation Buttons ....................................................................................... 624
4.3.6. Tools Menu ...................................................................................................................... 626
4.3.7. Window Menu .................................................................................................................. 627
4.3.8. View Menu ....................................................................................................................... 627
4.3.9. Options Menu .................................................................................................................. 628
4.3.10. Help Menu............................................................................................................................ 628
4.3.11. Animation Tools ................................................................................................................... 628
4.3.11.1. 3D View Mode ............................................................................................................. 628
4.3.11.2. 3D View Settings ......................................................................................................... 628
xvii
4.3.11.3. Animation setup and Control ....................................................................................... 628

4.4. Display Modification...................................................................................................................... 630
4.4.1. Display Property .............................................................................................................. 630
4.4.1.1. Title [2D, 3D] ............................................................................................................ 630
4.4.1.2. Contour [2D, 3D] ...................................................................................................... 631
4.4.1.3. Iso–Surface [3D] ...................................................................................................... 634
4.4.1.4. Vector [2D, 3D] ......................................................................................................... 635
4.4.1.5. Deflection [2D, 3D] ................................................................................................... 637
4.4.1.6. Point tracking [2D, 3D] ............................................................................................. 640
4.4.1.7. Flownet [2D, 3D] ...................................................................................................... 640
4.4.1.8. Axis [2D, 3D] ............................................................................................................ 642
4.4.1.9. Ruler [2D] ................................................................................................................. 642
4.4.1.10. Theme [2D, 3D] ........................................................................................................... 644
4.4.1.11. Selected mark [2D, 3D] ............................................................................................... 645
4.4.2. Graph Property ................................................................................................................ 646
4.4.2.1. Title [2D, 3D] ............................................................................................................ 646
4.4.2.2. X- axis and Y- axis [2D, 3D] ..................................................................................... 647
4.4.2.3. Data [2D, 3D] ........................................................................................................... 649
4.4.2.4. Legend [2D, 3D] ....................................................................................................... 650
4.4.2.5. Tick/Grid [2D, 3D] ..................................................................................................... 651
4.4.2.6. Step tracer [2D, 3D] ................................................................................................. 652
4.4.2.7. Background [2D, 3D] ................................................................................................ 653
4.4.2.8. Theme [2D, 3D] ........................................................................................................ 654
4.4.3. Set Coordinates ............................................................................................................... 655
4.4.3.1. Rectangular and Cylindrical co-ordinates ................................................................ 655
4.4.3.2. User Defined [2D, 3D] .............................................................................................. 656
4.4.3.3. Local (material axis) [2D, 3D] ................................................................................... 659
4.4.4. Set Viewport Property ...................................................................................................... 661
4.4.5. Set Lighting Property ....................................................................................................... 662
4.4.6. Color Bar Property ........................................................................................................... 665
4.4.6.1. General [2D, 3D] ...................................................................................................... 665
4.4.6.2. User-Defined [2D, 3D] .............................................................................................. 666
4.4.7. Set User Defined Variable Tracking ................................................................................ 667
4.4.8. Set Unit Conversion factors ............................................................................................. 669
4.5. Post-Processing features .............................................................................................................. 671
4.5.1. Simulation Summary........................................................................................................ 671
4.5.1.1. Operation ................................................................................................................. 673
4.5.1.2. Step .......................................................................................................................... 674
4.5.2. State Variables ................................................................................................................ 674
4.5.2.1. Different State variable types ................................................................................... 677
4.5.2.2. Normal Pressure [3D] ............................................................................................... 678
4.5.2.3. Plot type ................................................................................................................... 678
4.5.2.4. Deflection [2D, 3D] ................................................................................................... 679
4.5.2.5. Histogram [2D, 3D] ................................................................................................... 679
4.5.2.6. Scaling [2D, 3D] ....................................................................................................... 682
xviii
Table of Contents
4.5.2.7. Object Limits ............................................................................................................ 683

4.5.2.8. User Variables .......................................................................................................... 683
4.5.2.9. Usage ....................................................................................................................... 683
4.5.2.10. Interpreting state variables [2D, 3D] ........................................................................... 683
4.5.2.10.1. Damage .......................................................................................................... 683
4.5.2.10.2. Displacement .................................................................................................. 684
4.5.2.10.3. Density ............................................................................................................ 684
4.5.2.10.4. Strain .............................................................................................................. 684
4.5.2.10.5. Strain Rate ...................................................................................................... 686
4.5.2.10.6. Stress ............................................................................................................. 686
4.5.2.10.7. Velocity ........................................................................................................... 687
4.5.2.10.8. Back Stress .................................................................................................... 687
4.5.2.10.9. Normal Pressure............................................................................................. 687
4.5.2.10.10. Force.................................................................................................................. 687
4.5.2.10.11. Temperature ...................................................................................................... 688
4.5.2.10.12. Volume Fraction ................................................................................................ 688
4.5.2.10.13. Grain Size .......................................................................................................... 688
4.5.2.10.14. Hardness ........................................................................................................... 688
4.5.2.10.15. Dominant atom .................................................................................................. 688
4.5.2.10.16. Material .............................................................................................................. 688
4.5.2.10.17. User Variables ................................................................................................... 688
4.5.3. Load Stroke...................................................................................................................... 689
4.5.3.1. Show selected Objects............................................................................................. 689
4.5.3.2. Scale ........................................................................................................................ 689
4.5.3.3. Units ......................................................................................................................... 690
4.5.3.4. Operations ................................................................................................................ 690
4.5.3.5. Continuous stroke .................................................................................................... 690
4.5.3.6. Cumulative energy ................................................................................................... 690
4.5.3.7. Step tracer ................................................................................................................ 690
4.5.3.8. Absolute Value ......................................................................................................... 690
4.5.3.9. Causes of volume loss and their remedies include ................................................. 690
4.5.4. Point Tracking .................................................................................................................. 691
4.5.4.1. Adding Points ........................................................................................................... 692
4.5.4.2. Deleting Points ......................................................................................................... 692
4.5.4.3. Save the points to a file ............................................................................................ 692
4.5.4.4. Load the points to a file ............................................................................................ 692
4.5.4.5. Tracking options ....................................................................................................... 692
4.5.4.6. Save result to file ...................................................................................................... 693
4.5.4.7. Options ..................................................................................................................... 693
4.5.5. FlowNet ............................................................................................................................ 693
4.5.5.1. 2D Flownet ............................................................................................................... 693
4.5.5.1.1. Rectangular Grid [2D] ............................................................................................... 693
4.5.5.1.2. Polygon Pattern [2D] ................................................................................................ 698
4.5.5.1.3. Offset Pattern [2D] .................................................................................................... 701
4.5.5.2. 3D Flownet ............................................................................................................... 704
xix
4.5.5.2.1. Cubic pattern [3D] ..................................................................................................... 705

4.5.5.2.2. Grid Pattern [3D] ....................................................................................................... 707
4.5.5.2.3. Polygon pattern [3D] ................................................................................................. 711
4.5.5.2.4. 2D Offset [3D] ........................................................................................................... 714
4.5.5.2.5. Offset [3D]................................................................................................................. 716
4.5.5.2.6. Surface grid pattern [3D] .......................................................................................... 718
4.5.5.3. User Defined Flownet [2D, 3D] ................................................................................ 721
4.5.5.3.1. Example Case .......................................................................................................... 722
4.5.6. State variable distribution between 2 points .................................................................... 726
4.5.6.1. Straight line [2D, 3D] ................................................................................................ 726
4.5.6.2. Following Boundary.................................................................................................. 728
4.5.6.3. Circular pattern [3D] ................................................................................................. 731
4.5.7. Mirroring ........................................................................................................................... 733
4.5.7.1. Rotational symmetry ................................................................................................ 736
4.5.8. Data Extraction ................................................................................................................ 738
4.5.8.1. Data Type ................................................................................................................. 739
4.5.8.2. Object Data .............................................................................................................. 739
4.5.8.3. Output....................................................................................................................... 739
4.5.8.4. Steps ........................................................................................................................ 740
4.5.8.5. Files .......................................................................................................................... 740
4.5.8.6. Data File ................................................................................................................... 740
4.5.8.7. Extract ...................................................................................................................... 740
4.5.8.8. View.......................................................................................................................... 740
4.5.9. Slicing .............................................................................................................................. 740
4.5.9.1. Mode ........................................................................................................................ 741
4.5.9.2. Slicing plane display................................................................................................. 742
4.5.10. CCT Curve ........................................................................................................................... 742
4.5.11. Object Node Data ................................................................................................................ 742
4.5.12. Object Element Data ............................................................................................................ 744
4.5.13. Object Edge Data ................................................................................................................ 746
4.5.14. Animation controls and saving ............................................................................................. 747
4.5.15. 3D switcher and setup settings ............................................................................................ 749
4.5.15.1. 3D Setup Parameter: [2D, 3D] .................................................................................... 749
4.5.15.2. 3D viewer [2D, 3D] ...................................................................................................... 750
4.5.16. Database Comparison ......................................................................................................... 753
5 DEFORM Integrated Wizards ................................................................................................................ 757
5 1 F23 Template .................................................................................................................................. 757
5.1.1. F23 GUI and Pre Processor ................................................................................................... 758
5.1.1.1. F23 GUI Introduction .............................................................................................. 758
5.1.1.1.1. Display window ......................................................................................................... 760
5.1.1.1.2. Setting modification window ..................................................................................... 760
5.1.1.1.3. Project list window .................................................................................................... 761
5.1.1.1.4. Project record window .............................................................................................. 764
5.1.1.1.5. Graphical utilities window ......................................................................................... 764
5.1.1.2. F23 Pre Processor ................................................................................................. 769
xx
Table of Contents
5.1.1.2.1. Operation Setup ....................................................................................................... 769

5.1.1.2.2. Object definition ........................................................................................................ 776
5.1.1.2.3. 3D Conversion Tool .................................................................................................. 819
5.1.1.2.4. F23 Die Stress Operation ......................................................................................... 823
5.1.1.2.5. Manual BCC definition .............................................................................................. 833
5.1.1.2.6. File structure ............................................................................................................. 834
5.1.2. F23 Simulator.......................................................................................................................... 837
5.1.2.1. Starting the simulation............................................................................................ 839
5.1.3. F23 Post Processor ................................................................................................................ 841
5.1.3.1. Post Processor Overview ....................................................................................... 841
5.1.3.1.1. Project Record Window ............................................................................................ 844
5.1.3.1.2. Post processor tool box ............................................................................................ 847
5.1.3.1.3. F23 Post Processing for Cold Forming .................................................................... 852
5.1.3.1.4. F23 Post Processing for Hot / Warm Forming......................................................... 854
5.1.3.1.5. F23 Post Processing for Die Stress with Heat Transfer ........................................... 856
5.1.3.1.6. F23 Post Processing for Heat transfer ..................................................................... 860
5.2 Inverse Heat Transfer Wizard Manual......................................................................................... 864
5.2.1. Purpose of Inverse heat transfer wizard .......................................................................... 864
5.2.2. Methodology .................................................................................................................... 865
5.2.3. Display window ................................................................................................................ 866
5.2.4. Pre-Processor .................................................................................................................. 867
5.2.5. Running Optimization ...................................................................................................... 878
5.2.6. Results ............................................................................................................................. 879
Shape Rolling Manual ........................................................................................................................... 883
Ring Rolling Manual .............................................................................................................................. 885
Machining Template Manual ................................................................................................................. 887
Extrusion Template Manual ................................................................................................................... 888
6 Multiple Operations Layout .................................................................................................................... 889
6.1. Introduction to MO .......................................................................................................................... 889
6.2. MO Pre layout ................................................................................................................................. 893
6.2.1. Explorer ............................................................................................................................ 894
6.2.2. Operation Editor ............................................................................................................... 897
6.2.2.1. General options ........................................................................................................ 898
6.2.2.2. Operation options ..................................................................................................... 900
6.2.2.3. Object options .......................................................................................................... 901
6.2.3. Operation Tree ................................................................................................................. 905
6.2.3.1. Operation Tree Tool bar options .............................................................................. 906
6.2.3.2. Object Tree Right Mouse button (RMB) options ...................................................... 909
6.2.4. Property Editor ................................................................................................................. 910
6.2.5. Message tab .................................................................................................................... 910
6.2.6. Step Editor ....................................................................................................................... 911
6.2.7. Graphics window ............................................................................................................. 913
6.3. MO Simulation layout ..................................................................................................................... 921
6.3.1. Simulation Options ........................................................................................................... 921
6.3.1.1. Run ........................................................................................................................... 922
xxi
6.3.1.2. Run Options ............................................................................................................. 923

6.3.1.3. Stop .......................................................................................................................... 927
6.3.1.4. Continue ................................................................................................................... 927
6.3.1.5. Refresh ..................................................................................................................... 928
6.3.2. Simulation Jobs tab ......................................................................................................... 928
6.3.3. Simulation Message tab .................................................................................................. 928
6.3.4. Simulation LOG tab ......................................................................................................... 929
6.3.5. Simulation graphics ......................................................................................................... 929
6.3.5.1. Simulation graphics tool bar options: ....................................................................... 929
6.3.5.2. Right Mouse Button options ..................................................................................... 933
6.4. MO Post layout ............................................................................................................................... 938
6.4.1. Step browser .................................................................................................................... 939
6.4.1.1. Step Tools ................................................................................................................ 939
6.4.1.2. Step list magnifier ..................................................................................................... 940
6.4.1.3. Step Selection options ............................................................................................. 940
6.4.1.4. Right Mouse button step browser options................................................................ 940
6.4.2. Graphics window ............................................................................................................. 943
6.4.3. Post Tools ........................................................................................................................ 943
6.4.3.1. State variables ......................................................................................................... 945
Different State variable types ..................................................................................................... 946
6.4.3.1.1. Display options ......................................................................................................... 948
6.4.3.1.2. State variables settings [2D,3D] ............................................................................... 949
6.4.3.1.3. Controls settings ....................................................................................................... 950
6.4.3.1.4. Deflection settings [2D, 3D] ...................................................................................... 951
6.4.3.1.5. Reference settings .................................................................................................... 951
6.4.3.1.6. Tool wear settings .................................................................................................... 954
6.4.3.2. Tools......................................................................................................................... 956
6.4.3.2.1. Summary [2D,3D]: .................................................................................................... 956
6.4.3.2.2. Load-Stroke [2D,3D]: ................................................................................................ 956
6.4.3.2.3. Point tracking [2D,3D]:.............................................................................................. 956
6.4.3.2.4. Flownet [2D,3D]: ....................................................................................................... 956
6.4.3.2.5. Animation setup [2D,3D]:.......................................................................................... 956
6.4.3.2.6. 3D viewer [3D]: ......................................................................................................... 957
6.4.3.2.7. Mirroring [3D]: ........................................................................................................... 957
6.4.3.2.8. Slicing [3D]: .............................................................................................................. 957
6.4.4. Output tree ....................................................................................................................... 957
6.5. Menu options .................................................................................................................................. 960
6.5.1. Pre Mode menu bar options ............................................................................................ 960
6.5.1.1. File Menu.................................................................................................................. 960
6.5.1.1.1. New Project (Ctrl+N)................................................................................................ 961
6.5.1.1.2. Open Project (Ctrl+O) ............................................................................................... 962
6.5.1.1.3. Save (Ctrl+S) .......................................................................................................... 962
6.5.1.1.4. Import (Ctrl+D) .......................................................................................................... 962
6.5.1.1.5. Export ....................................................................................................................... 962
6.5.1.1.6. Folder options ........................................................................................................... 962
xxii
Table of Contents
6.5.1.1.7. Recent Projects ........................................................................................................ 962

6.5.1.1.8. Close (Ctrl+W) .......................................................................................................... 963
6.5.1.1.9. Quit (Ctrl+Q) ............................................................................................................. 963
6.5.1.2. Viewport Menu ......................................................................................................... 963
6.5.1.2.1. Refresh (F5) ........................................................................................................... 963
6.5.1.2.2. View Fit (F3) ............................................................................................................ 964
6.5.1.2.3. Iso view ..................................................................................................................... 964
6.5.1.2.4. Screen upward ......................................................................................................... 964
6.5.1.2.5. View point , , , , , ....................................................................................................... 964
6.5.1.2.6. Load and Save ......................................................................................................... 965
6.5.1.2.7. Lighting ..................................................................................................................... 966
6.5.1.3. Display menu ........................................................................................................... 968
6.5.1.3.1. Shading (F6) ............................................................................................................. 969
6.5.1.3.2. Wireframe (F7) ......................................................................................................... 969
6.5.1.3.3. Shading and Wireframe (F8) .................................................................................... 969
6.5.1.3.4. Feature line or Surface patch ................................................................................... 969
6.5.1.3.5. Add feature line ........................................................................................................ 969
6.5.1.4. Mouse Menu ............................................................................................................ 969
6.5.1.4.1. Measurement ............................................................................................................ 970
6.5.1.4.2. Explorer (select, pan, rotate, zoom) ......................................................................... 970
6.5.1.4.3. Select ........................................................................................................................ 971
6.5.1.4.4. Pan (Shift+LMB) ....................................................................................................... 971
6.5.1.4.5. Rotate (Ctrl+LMB)..................................................................................................... 971
6.5.1.4.6. Dynamic zoom (Alt+LMB) ......................................................................................... 971
6.5.1.4.7. Box Zoom (Ctrl+Alt+LMB) ........................................................................................ 972
6.5.1.5. Tool Menu ................................................................................................................ 972
6.5.1.5.1. Object Nodes ............................................................................................................ 972
6.5.1.5.2. Object Elements ....................................................................................................... 972
6.5.1.5.3. Image setup (Ctrl+M) ................................................................................................ 973
6.5.1.5.4. Capture image (Ctrl+I) .............................................................................................. 973
6.5.1.5.5. Capture Image to clipboard (Ctrl+Shift+I) ................................................................. 973
6.5.1.6. Options Menu ........................................................................................................... 973
6.5.1.6.1. Environment ............................................................................................................. 974
6.5.1.6.2. Preferences .............................................................................................................. 983
6.5.1.7. Project Menu ............................................................................................................ 987
6.5.1.8. Help Menu ................................................................................................................ 988
6.5.1.8.1. Deform manual (F1) ................................................................................................. 989
6.5.1.8.2. What's this? (Shift+F1) .......................................................................................... 989
6.5.1.8.3. About SFTC .............................................................................................................. 989
6.5.1.8.4. About ........................................................................................................................ 989
6.5.2. Simulation Mode menu bar options ................................................................................. 989
6.5.2.1. Simulation Menu ...................................................................................................... 990
6.5.2.1.1. Run (F9) or Submit simulation of the current Project ............................................... 990
6.5.2.1.2. Stop (F10) ................................................................................................................. 990
6.5.2.1.3. Continue (Ctrl+ F9) ................................................................................................... 990
xxiii
6.5.2.1.4. Add to Batch Queue (Ctrl+Shift+A) .......................................................................... 990

6.5.2.1.5. Run options .............................................................................................................. 991
6.5.2.1.6. Process Monitor ........................................................................................................ 991
6.5.3. Post Mode menu bar options ........................................................................................... 991
6.5.4. Tool bar options ............................................................................................................... 991
6.5.4.1. Switch to guided mode ............................................................................................. 992
6.5.4.2. Switch to expert mode.............................................................................................. 992
6.5.4.3. Boolean .................................................................................................................... 992
6.5.4.4. Data Interpolation ..................................................................................................... 992
6.5.4.5. Slicing ....................................................................................................................... 993
6.6. File structure ................................................................................................................................... 995
6.6.1. Normal MO Project Structure........................................................................................... 995
6.6.2. MO DOE Project File structure ........................................................................................ 996
6.6.3. MO Die Stress Project File Structure ............................................................................... 997
6.6.4. Report Generation ........................................................................................................... 998
6.6.5. MO Wizard and Operation specific Files ......................................................................... 998
6.6.6. Operation Specific Important Files .................................................................................. 999
6 7 Operations ..................................................................................................................................... 1001
Operations Setup ............................................................................................................................. 1002
Forming ........................................................................................................................................ 1003
6.7.1.1.Introduction to Forming................................................................................................. 1003
6.7.1.2. Forming 2D Setup ....................................................................................................... 1005
6.7.1.3. Forming 3D Setup ....................................................................................................... 1056
2D Geometry Editing .................................................................................................................... 1133
2D Geometry Editing ................................................................................................................ 1133
Forming Express .......................................................................................................................... 1134
Introduction to Forming Express 2D ......................................................................................... 1134
Forming Express 2D Setup ...................................................................................................... 1135
Die Stress ..................................................................................................................................... 1137
6.7.4.1. Introduction to Die Stress ............................................................................................ 1137
6.7.4.2. Die Stress 2D Manual .................................................................................................. 1138
Multiple Blow Hammer-2D ........................................................................................................... 1183
Introduction to Multiple blow Hammer 2D ................................................................................ 1183
Multiple Blow Hammer 2D Setup .............................................................................................. 1184
Heat Treatment ............................................................................................................................ 1185
6.7.6.1 Heat Treatment Manual ................................................................................................ 1185
6.7.6.1.1. Introduction to Heat Treatment ................................................................................ 1185
6.7.6.2. 2D Heat Treatment Wizard Manual ............................................................................. 1187
HT Furnace-3D............................................................................................................................. 1237
Introduction to 3D HT Furnace ................................................................................................. 1237
3D HT Furnace Setup ............................................................................................................... 1238
Heat Transfer Operations 2D and 3D .......................................................................................... 1239
xxiv
Table of Contents
Heating Express 2D and 3D ..................................................................................................... 1239

Heat Transfer Operations Setup ............................................................................................... 1240
Machining Distortion ..................................................................................................................... 1241
6.7.9.1.Introduction to Machining Distortion ............................................................................. 1241
6.7.9.2.Machining Distortion 2D Setup ..................................................................................... 1243
Cogging ........................................................................................................................................ 1277
6.7.1.10.Introduction to Cogging Wizard .................................................................................. 1277
2D to 3D Converter ...................................................................................................................... 1331
2D to 3D Converter ................................................................................................................... 1331
Report Generation ........................................................................................................................ 1332
6.7.13. Report Generation operation ........................................................................................ 1332
6 8 Operations Management ............................................................................................................... 1366
6.8.1. Connecting Operations and passing objects ......................................................................... 1366
6.8.1.1. Connecting Operations ........................................................................................ 1366
6.8.1.2. Passing objects .................................................................................................... 1369
6.8.2. Read from DB concept .......................................................................................................... 1374
6.8.3. Editing Operations ................................................................................................................. 1381
6.8.4. Upgrading Operations ............................................................................................................ 1386
6.8.5. Adding Cycles ........................................................................................................................ 1390
6.8.5.1. Introduction .......................................................................................................... 1390
6.8.5.2. Add Cycles ........................................................................................................... 1390
6.8.5.3. Delete Cycles ....................................................................................................... 1392
6.8.5.4. Changing the number of cycles ........................................................................... 1393
6.8.5.5. Change the name of the cycle operation ............................................................. 1393
6.8.5.6. Moving operations (Drag and Drop) ..................................................................... 1394
6.8.5.7. Examples ............................................................................................................. 1395
6 9 DOE Setup .................................................................................................................................... 1398
6.9.1. Introduction to DOE ............................................................................................................... 1398
6.9.2. DOE and DOE Output Operation Setup ................................................................................ 1401
6.9.2.1. Adding DOE Study ............................................................................................... 1401
6.9.2.2. Defining DOE Variables ....................................................................................... 1402
6.9.2.3. Failed DOE variable definition ............................................................................. 1416
6.9.2.4. Deleting DOE variable.......................................................................................... 1416
6.9.2.5. DOE Table ........................................................................................................... 1417
6.9.2.6. DOE Sampling ..................................................................................................... 1419
6.9.2.6.1. Latin Hypercube Sampling ..................................................................................... 1419
6.9.2.6.2. Full Factorial Sampling ........................................................................................... 1420
6.9.2.6.3. User defined Sampling ........................................................................................... 1421
6.9.2.7. Defining DOE output operation ............................................................................ 1421
6.9.2.7.1. Select operation and object .................................................................................... 1421
6.9.2.7.2. Define Region of Interest ........................................................................................ 1422
6.9.2.7.3. Define outputs ........................................................................................................ 1426
6.9.2.7.4. Define Variable Constraints .................................................................................... 1432
6.9.2.7.5. Define Fill Constraints ............................................................................................ 1433
xxv
6.9.3. DOE Simulation Running and Monitoring .............................................................................. 1436

6.9.4. DOE Post Processor .............................................................................................................. 1441
6.9.4.1. Introduction .......................................................................................................... 1441
6.9.4.2. DOE Post Components ........................................................................................ 1441
6.9.4.3. Graphics view ....................................................................................................... 1442
6.9.4.4. Table View ........................................................................................................... 1444
6.9.4.5. Response Surface Plots ( and ) ........................................................................... 1445
6.9.4.6. Sensitivity Plot ...................................................................................................... 1447
6.9.4.7. Tornado Chart ...................................................................................................... 1449
6.9.4.8. Scatter Plot ........................................................................................................... 1451
6.9.4.9. Histogram Plot ...................................................................................................... 1452
6 11 Die Stress Study .......................................................................................................................... 1455
6.11.1. Introduction to Die Stress Study .......................................................................................... 1455
6.11.2. Die Stress Study for 2D Setup ............................................................................................. 1457
6.11.2.1. How to add Die stress study for 2D setup................................................................ 1457
6.11.2.2. Step selection ........................................................................................................... 1458
6.11.2.3. Objects window ........................................................................................................ 1459
6.11.2.4. Object Types ............................................................................................................ 1460
6.11.2.5. Dies .......................................................................................................................... 1461
6.11.2.5.1. General ......................................................................................................... 1461
6.11.2.5.2. Geometry ...................................................................................................... 1461
6.11.2.5.3. Object Mesh ................................................................................................. 1462
6.11.2.5.4. Force Interpolation........................................................................................ 1463
6.11.2.5.5. Object Material ............................................................................................. 1465
6.11.2.5.6. Object boundary conditions .......................................................................... 1465
6.11.2.5.7. Initialize ......................................................................................................... 1468
6.11.2.5.8. Fixtures ......................................................................................................... 1469
6.11.2.6. Controls .................................................................................................................... 1469
6.11.2.7. Inter-object relations ................................................................................................. 1471
6.11.2.8. Simulation control ..................................................................................................... 1472
6.11.2.8.1. Number of simulation steps .......................................................................... 1472
6.11.2.8.2. Step increment to save ................................................................................. 1472
6.11.2.8.3. Step increment control.................................................................................. 1473
6.11.2.9. Generate DB ............................................................................................................ 1473
6.11.2.9.1. Check data ................................................................................................... 1473
6.11.2.9.2. Generate database ....................................................................................... 1474
6.11.2.9.3. Append key file ............................................................................................. 1474
6.11.3. Die Stress Study for 3D setup ............................................................................................. 1476
6.11.3.2. Step selection ........................................................................................................... 1477
6.11.3.3. Objects window ........................................................................................................ 1478
6.11.3.4. Object Types ............................................................................................................ 1479
6.11.3.5. Dies .......................................................................................................................... 1480
6.11.3.5.1. General ......................................................................................................... 1480
6.11.3.5.2. Geometry ...................................................................................................... 1480
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Table of Contents
6.11.3.5.3. Object Mesh ................................................................................................. 1481

6.11.3.5.5. Object Material ............................................................................................. 1484
6.11.3.5.7. Initialize ......................................................................................................... 1487
6.11.3.5.8. Fixtures ......................................................................................................... 1488
6.11.3.6. Controls .................................................................................................................... 1488
6.11.3.9. Generate DB ............................................................................................................ 1492
6.11.3.9.1. Check data ................................................................................................... 1492
6.11.3.9.3. Append key file ............................................................................................. 1493
7 Next Gen Post Processor..................................................................................................................... 1495
7.1. Introduction to Next Gen Post Processor ..................................................................................... 1495
7.2. Next Gen Post Processor Layout ................................................................................................. 1498
7.2.1. Step View Window ......................................................................................................... 1499
7.2.1.1. Step tools and operation selection options ............................................................ 1499
7.2.1.2. Steps Selection options.......................................................................................... 1500
7.2.1.3. Step list.................................................................................................................. 1500
7.2.2. Graphics window ........................................................................................................... 1501
7.2.3. Post features settings modifications window ................................................................. 1501
7.2.4. Object Tree .................................................................................................................... 1501
7.2.5. Report Generation ......................................................................................................... 1501
7.2.6. Post Features ................................................................................................................ 1502
7.2.6.1. State Variables ....................................................................................................... 1502
7.2.6.2. Region of Interest ................................................................................................... 1503
7.2.6.3. Summary Graphs .................................................................................................. 1507
7.2.6.4. Load/Stroke Graphs .............................................................................................. 1510
7.2.6.5. Point Tracking ........................................................................................................ 1512
7.2.6.6. Coupon Data Extraction ......................................................................................... 1517
7.2.6.7. Flownet Tracking .................................................................................................... 1520
7.2.6.8. Set User defined variable tracking ......................................................................... 1521
7.2.6.9. Mirror Symmetry ..................................................................................................... 1523
7.2.6.10. Slicing ........................................................................................................................ 1530
7.2.6.11. Data Extraction .......................................................................................................... 1534
7.2.6.12. Measurement options ................................................................................................ 1536
7.2.6.13. Animation Setup ........................................................................................................ 1537
7.2.6.14. 3D viewer and setup [2D] .......................................................................................... 1540
7.2.6.15. 3D Setup Parameter [2D] .......................................................................................... 1541
7.2.6.16. Text and Image Annotations .................................................................................... 1542
7.2.6.17. Object Nodes ............................................................................................................ 1546
xxvii
7.2.6.18. Object Elements ........................................................................................................ 1547

7.3. Report Generation ........................................................................................................................ 1551
7.3.1. Introduction: ................................................................................................................... 1551
7.3.2. Report ............................................................................................................................ 1551
7.3.3. Chapter .......................................................................................................................... 1553
7.3.3.1. Chapter title ............................................................................................................ 1555
7.3.3.2. Operation range selection ...................................................................................... 1555
7.3.3.3. Sections.................................................................................................................. 1555
7.3.3.3.1. Summary ................................................................................................................ 1555
7.3.3.3.2. Graph (load-Stroke) ................................................................................................ 1557
7.3.3.3.3. State Variable ......................................................................................................... 1559
7.3.3.3.4. Region of Interest ................................................................................................... 1565
7.3.3.3.5. Coupon ................................................................................................................... 1568
7.3.3.3.6. Point Tracking ......................................................................................................... 1570
7.3.3.3.7. Flownet ................................................................................................................... 1573
7.3.3.3.8. Metal Flow .............................................................................................................. 1576
7.3.3.3.9. Post user variables tracking ................................................................................... 1578
7.3.3.3.10. User defined ................................................................................................. 1583
7.4. Editing Chapters ........................................................................................................................... 1594
7.5. Working with DB in PIP mode ...................................................................................................... 1597
8 User Routines ...................................................................................................................................... 1603
User Routine for DEFORM-2D ............................................................................................................ 1603
8.1. 2D User Routines...................................................................................................................... 1604
8.2. 2D User Defined FEM Routines .............................................................................................. 1607
8.2.1. Summary of subroutines and calling structure of user-defined FEM routines ........... 1610
8.2.2. Passing data to user routines from the Preprocessor ................................................ 1613
8.2.3. User defined flow stress routines (USRMTR) ............................................................ 1615
8.2.4. User defined movement control (USRDSP) ............................................................... 1619
8.2.5. User defined node and element value (USRUPD) .................................................... 1624
8.2.6. User defined damage models (USRDMG) ................................................................. 1629
8.2.7. User defined material models (USRMAT).................................................................. 1632
8.2.8. User defined nodal boundary conditions (USRBCC) ................................................. 1636
8.2.9. User defined lubricant heat transfer (USRBCC2) ...................................................... 1640
8.2.10. User defined general routine (USRMSH) ....................................................................... 1644
8.2.11. Compiling user routines for UNIX platforms................................................................... 1648
8.2.12. Running the modified FEM engine for UNIX platforms .................................................. 1648
8.2.13. Running the modified FEM engine for Windows platforms ............................................ 1649
8.3. 2D User-Defined Post-Processing Routines ........................................................................... 1651
8.3.1. User defined post-processing (USRVAR) .................................................................. 1652
8.3.2. Compiling user routines on Linux/Unix ...................................................................... 1654
8.3.3. Compiling user routines on Windows ......................................................................... 1655
8.3.4. Running the modified post-processor ........................................................................ 1655
8.4 3D User Routines....................................................................................................................... 1657
8.4.1. 3D User defined FEM routines ................................................................................... 1663
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Table of Contents
8.4.1.1. User defined data (USRDEF) ............................................................................. 1663

8.4.1.2. User defined flow stress routines (USRMTR) .................................................... 1665
8.4.1.3. User defined movement control (USRDSP) ....................................................... 1669
8.4.1.4. User defined node and element value (USRUPD) ............................................. 1675
8.4.1.5. User defined damage models (USRDMG) ....................................................... 1679
8.4.1.6. User defined general routine (USRMSH) ........................................................... 1681
8.4.2. Running the modified FEM engine for UNIX platforms .............................................. 1685
8.4.3. 3D User defined post-processing routines ................................................................. 1687
8.4.5. Compiling post-processing user routines on UNIX machines .................................... 1690
8.4.6. Running the modified post-processor in UNIX ........................................................... 1690
8.4.7. Compiling post-processing user routines on Windows machines.............................. 1691
9 Appendices .......................................................................................................................................... 1693
Appendix I: Elementary Concepts in Metalforming and Finite Element Analysis............................... 1693
AI.1. Definition of stress, strain and strain rate ............................................................................... 1693
AI.2. Introduction to FEM theory ..................................................................................................... 1700
AI.3. Modeling Material Behavior in FEM ..................................................................................... 1703
Appendix II: Installation of DEFORM v11.0 in windows ...................................................................... 1706
AII.1. INTRODUCTION .......................................................................................................... 1706
AII.2. INSTALLATION REQUIREMENTS .............................................................................. 1706
AII.3. INSTALLING THE SECURITY KEY DEVICE .............................................................. 1706
AII.4. INSTALLING DEFORM v11.0 IN WINDOWS .............................................................. 1707
AII.5. TROUBLE SHOOTING ................................................................................................ 1756
AII.6. QUESTIONS / PROBLEMS ......................................................................................... 1761
Appendix III: Installation of DEFORM V10.2.1 in UNIX or LINUX ....................................................... 1763
AIII.1. INTRODUCTION ........................................................................................................... 1763
AIII.2. INSTALLATION REQUIREMENTS ............................................................................... 1763
AIII.3. OBTAINING AND INSTALLING THE SUPPORTING SOFTWARE ............................. 1764
AIII.3.1. Obtaining and Installing LZMA ............................................................................... 1764
AIII.3.2. Obtaining and Installing GNU tar on Linux ............................................................. 1765
AIII.3.3. Obtaining and Installing GNU tar on HP-UX........................................................... 1765
AIII.4. OBTAINING AND INSTALLING THE DEFORM SOFTWARE ..................................... 1765
AIII.4.1. Installation Procedure ............................................................................................. 1765
AIII.4.1.1. Install the Sentinel Key Driver for Linux systems ................................................... 1765
AIII.4.1.2. Installing DEFORM and/or License Manager on Linux .......................................... 1766
AIII.4.1.3. Instructions for running 64bit DEFORM on Linux operating systems .................... 1769
AIII.4.1.4. Installing DEFORM and/or License Manager on HP-UX ....................................... 1769
AIII.4.1.5. Setup a user account ............................................................................................. 1770
AIII.5. HP Intel Xeon XC-2000 Cluster updates ....................................................................... 1771
AIII.5.1. How to install Open Fabrics Infiniband support ...................................................... 1771
AIII.6. System Execution .......................................................................................................... 1772
AIII.7. QUESTIONS / PROBLEMS .......................................................................................... 1773
Appendix IV: License Manager .......................................................................................................... 1775
Appendix V: Launching the Simulation Engine from a Command Prompt (Windows only) ................ 1777
Appendix VI: Running DEFORM in text mode ................................................................................... 1780
xxix
AVI.1. Assembling input data..................................................................................................... 1780

AVI.2. Brief Introduction to Keywords ........................................................................................ 1781
AVI.3. Help For Optimization Users ........................................................................................... 1782
AVI.4. Running a Simulation ...................................................................................................... 1782
AVI.5. Extracting the Results ..................................................................................................... 1782
Appendix VII: Determining 'R' coefficients for anisotropy models ....................................................... 1785
Appendix VIII: The Elasto-Plastic Model ............................................................................................. 1788
AVIII.1. Material Properties ............................................................................................................. 1788
AVIII.2. Object data ......................................................................................................................... 1789
AVIII.3. Solution procedure ............................................................................................................. 1790
AVIII.4. Strain Definition .................................................................................................................. 1790
AVIII.5. Advice on Predicting Springback ....................................................................................... 1790
AVIII.6. Note on Convergence issues with Elasto-Plastic material models .................................... 1790
AVIII.7. DEFORM convention rule for material interpolation .......................................................... 1791
AVIII.8. Comments on “Flow curve definition for Rate-dependent material” .................................. 1791
Appendix IX: Part is deforming, but strain does not accumulate......................................................... 1796
Appendix X: Checking the forming loads results of a simulation ....................................................... 1800
Appendix XI: Preventing leakage of nodes in sectioned simulations .................................................. 1803
Appendix XII: Generating a Circular Geometry With a Hole .............................................................. 1807
Appendix XIII: 2D Topology Definition and Multiple Material Groups ................................................ 1812
AXIII.1. 2D Topology Definition ....................................................................................................... 1813
AXIII.2. User Interface for Topology Building ................................................................................. 1814
AXIII.3. Summary ............................................................................................................................ 1819
AXIII.4. Applications of Multiple Material Groups ........................................................................... 1820
AXIII.5. Two examples from the references.................................................................................... 1820
Appendix XIV : Near-surface mesh functions...................................................................................... 1822
Appendix XV: Modeling of a Spring-Loaded Sliding Die Using Force Controlled Objects .................. 1829
Appendix XVI: Finer Points on Using Force Controlled Dies ............................................................. 1835
AXVI.1. Objective ............................................................................................................................ 1835
AXVI.2. Theory................................................................................................................................ 1835
AXVI.3. Solution .............................................................................................................................. 1835
Appendix XVII: Details of Movement control in Spinning motion.KEY ................................................ 1837
AXVII.1. Introduction ............................................................................................................... 1837
AXVII.2. Movement controls for spinning ............................................................................... 1837
Appendix XVIII: Rotating Workpiece Simulations ............................................................................... 1840
AXVIII.1. Moving tools about a non-spinning workpiece ........................................................... 1841
AXVIII.2. Spinning Workpiece.................................................................................................... 1843
Appendix XIX: The Double Concave Corner Constraint ..................................................................... 1848
Appendix XX: Die Stress Analysis - Theory ....................................................................................... 1852
AXX.1. Overview ............................................................................................................................. 1852
AXX.2. Types of analyses ............................................................................................................... 1853
AXX.3. Practical Considerations ..................................................................................................... 1855
AXX.4. Die Failure Modes .............................................................................................................. 1856
AXX.5. Required Data..................................................................................................................... 1857
AXX.6. Die Stress Setup ................................................................................................................. 1857
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Table of Contents
AXX.7. Defining a Press Fit ............................................................................................................ 1858

AXX.8. Quick Summary of Shrink Fit Boundary Condition ............................................................. 1858
AXX.9. Important Measurements of Stress .................................................................................... 1860
AXX.10. Interpretation of Stress ............................................................................................... 1861
Appendix XXI: Die Stress Analysis in DEFORM Theory and Practical Applications ......................... 1865
AXXI.1. Die Stress Analysis Importance .............................................................................. 1865
AXXI.2. Modes of Die Failure ............................................................................................... 1865
AXXI.3. Die Stress State ....................................................................................................... 1865
AXXI.4. Die Stress Analysis Effective Stress ....................................................................... 1866
AXXI.5. Die Stress Analysis Fatigue Failure ........................................................................ 1867
AXXI.6. Die Stress Example Low Complexity ...................................................................... 1867
AXXI.7. Die Stress Example Medium Complexity ................................................................ 1868
AXXI.8. Die Stress Example - High Complexity ................................................................... 1869
AXXI.9. Coupled Die Stress Analysis ................................................................................... 1870
Appendix XXII: How to do coupled die stress analysis for 3D models ................................................ 1873
Appendix XXIII: Setting up fracture with element deletion in DEFORM-2D ........................................ 1877
Appendix XXIV: Fracture with Element Deletion and Damage Softening ........................................... 1882
Appendix XXV: Setting up induction heating in DEFORM-2D ............................................................ 1888
AXXV.1. Defining the simulation ............................................................................................... 1888
AXXV.2. Post-Processing the simulation .................................................................................. 1892
Appendix XXVI: A Theoretical Background to Resistance Heating Concepts Implemented in DEFORM-
2D ........................................................................................................................................................ 1894
Appendix XXVII: Running an inertia weld simulation in DEFORM ..................................................... 1898
Appendix XXVIII: Running creep simulations in DEFORM-2D .......................................................... 1900
Appendix XXIX: Adding Gas Trap Calculation to a Simulation ........................................................... 1905
Appendix XXX: Sheet Forming in DEFORM-3D ................................................................................. 1908
AXXX.1. Theory - Anisotropy ..................................................................................................... 1908
AXXX.2. Theory – Assumed Strain Formulation ....................................................................... 1910
AXXX.3. Simulation Principles ................................................................................................... 1911
AXXX.4. Example: Square cup drawing process ...................................................................... 1911
AXXX.5. Example: Cylindrical cup drawing process ................................................................. 1913
Appendix XXXI: Shape Rolling Simulation Overview .......................................................................... 1918
AXXXI.1. System features ........................................................................................................... 1918
AXXXI.2. Characteristics ............................................................................................................. 1918
Appendix XXXII: Setting up Steady State Extrusion ........................................................................... 1921
AXXXII.1. General description ........................................................................................................ 1921
AXXXII.2. Data preparation ............................................................................................................ 1921
AXXXII.3. Some techniques for running the steady state extrusion ............................................... 1922
AXXXII.4. EXTDIE.DAT preparation ............................................................................................... 1925
AXXXII.5. EDGEINFO.DAT ............................................................................................................ 1926
AXXXII.6. PKVEL.DAT.................................................................................................................... 1926
Appendix XXXIII: Setting up 3D machining models ............................................................................ 1929
Appendix XXXIV: Data Files ................................................................................................................ 1933
Appendix XXXV: How to Create DEFORM Animations for Distribution ............................................. 1947
AXXXV.1. Recommended Method ................................................................................................. 1947
xxxi
AXXXV.2. Legacy Method .............................................................................................................. 1948

10 License Manager ................................................................................................................................ 1951
10.1. DEFORM License Setup ............................................................................................................ 1951
10.1.1. Computer configuration requirements ............................................................................... 1951
10.1.2. Computer Locations in DEFORM Setup ............................................................................ 1951
10.1.3. How to setup the new license configuration ...................................................................... 1952
10.2. License Monitoring ..................................................................................................................... 1968
10.3. Monitoring Services ................................................................................................................ 1971
10.4. Trouble Shooting License Issues ............................................................................................... 1973
10.4.1. Identifying License Server 3.0.4 Problem .......................................................................... 1973
10.4.2. Solving License Server v3.0.4 Problem: Specific Topic Issues......................................... 1974
10.4.2.1. Password problem .................................................................................................... 1974
10.4.2.2. Hardware key problem check list .............................................................................. 1974
10.4.2.3. Old license is running ................................................................................................ 1974
10.4.2.4. Register service problem .......................................................................................... 1974
10.4.2.5. Service startup problem ............................................................................................ 1975
10.4.3. Miscellaneous Service Related Notes ............................................................................... 1975
10.4.3.1. Instructions to unregister the service ........................................................................ 1975
11 Keyword Documentation .................................................................................................................... 1979
Keyword Documentation for DEFORM-2D.......................................................................................... 1979
A ....................................................................................................................................................... 1979
B ....................................................................................................................................................... 1994
C....................................................................................................................................................... 2018
D....................................................................................................................................................... 2059
E ....................................................................................................................................................... 2117
F ....................................................................................................................................................... 2177
G ...................................................................................................................................................... 2230
H....................................................................................................................................................... 2269
I ........................................................................................................................................................ 2286
J ....................................................................................................................................................... 2307
K ....................................................................................................................................................... 2310
L ....................................................................................................................................................... 2314
M ...................................................................................................................................................... 2331
N....................................................................................................................................................... 2384
O ...................................................................................................................................................... 2399
P ....................................................................................................................................................... 2417
R....................................................................................................................................................... 2448
S ....................................................................................................................................................... 2470
T ....................................................................................................................................................... 2517
U....................................................................................................................................................... 2580
V ....................................................................................................................................................... 2602
W ...................................................................................................................................................... 2619
Y ....................................................................................................................................................... 2635
Z ....................................................................................................................................................... 2641
xxxii
Table of Contents
A ....................................................................................................................................................... 2648
B ....................................................................................................................................................... 2652
C....................................................................................................................................................... 2660
D....................................................................................................................................................... 2671
E ....................................................................................................................................................... 2696
F ....................................................................................................................................................... 2724
G ...................................................................................................................................................... 2737
H....................................................................................................................................................... 2741
I ........................................................................................................................................................ 2743
M ...................................................................................................................................................... 2746
N....................................................................................................................................................... 2769
O ...................................................................................................................................................... 2771
P ....................................................................................................................................................... 2784
R....................................................................................................................................................... 2794
S ....................................................................................................................................................... 2803
T ....................................................................................................................................................... 2821
U....................................................................................................................................................... 2825
V ....................................................................................................................................................... 2828
W ...................................................................................................................................................... 2830
Y ....................................................................................................................................................... 2846
Labs ......................................................................................................................................................... 2853
Quick reference ................................................................................................................................... 2853
Quick Reference .............................................................................................................................. 2853
Cold Forming ................................................................................................................................... 2854
Hot Forming ..................................................................................................................................... 2859
12 2D Labs Integrated ......................................................................................................................... 2867
Integrated 2D Labs Index ................................................................................................................ 2867
Basic labs ......................................................................................................................................... 2870
Lab 1. Geometry Manipulation - XYR Format ........................................................................... 2870
1.1. Creating a New Problem .............................................................................................. 2870
1.2. Setting Simulation Controls .......................................................................................... 2874
1.3. Creating a New Object ................................................................................................. 2875
1.4. Display Manipulation .................................................................................................... 2877
1.5. Point Selection .............................................................................................................. 2877
1.6. Saving the Problem ...................................................................................................... 2877
1.7. Exiting DEFORM-2D3D ................................................................................................ 2877
Lab 2. Geometry Input - IGES Files ...................................................................................... 2879
2.3. Creating New Objects ................................................................................................... 2879
Lab 3. Geometry Input - Geometry Correction ...................................................................... 2884
xxxiii

Lab 4. Uniform Mesh Generation .......................................................................................... 2888
4.1. Opening a Previously Saved Problem .......................................................................... 2888
4.2. Generating a Uniform Mesh ......................................................................................... 2888
Lab 5. Spike Forging - Mesh Generation for Billet ................................................................ 2893
5.2. Setting Meshing Parameters and Generating the Mesh .............................................. 2893
Lab 6. Spike Forging - Mesh Generation for Dies ................................................................. 2898
6.2. Changing Simulation Controls ...................................................................................... 2898
6.3. Generating Mesh on the Dies ....................................................................................... 2898
6.4. Saving the Problem under a Different Name................................................................ 2899
Lab 7. Spike Forging - Die Positioning .................................................................................. 2902
7.2. Changing Object Positioning ........................................................................................ 2902
Lab 8. Spike Forging - Pre-Processing ................................................................................. 2907
8.1. Opening a Previous Simulation .................................................................................... 2907
8.3. Setting Object Temperature ......................................................................................... 2908
8.4. Importing Material Data ................................................................................................ 2908
8.5. Defining Deformation Boundary Conditions ................................................................. 2909
8.6. Assigning a Velocity to the Primary Die ....................................................................... 2909
8.7. Assigning Inter-Object Relationships ........................................................................... 2910
8.8. Generating a Database ................................................................................................ 2914
8.10. Exiting DEFORM-2D3D ........................................................................................ 2914
Lab9. Spike Forging Simulation & Post-Processing ......................................................... 2917
9.2. Starting the Simulation ................................................................................................ 2917
9.3. Post-Processing the Results ........................................................................................ 2918
Lab 10. Heat Transfer - Heating Billet in Furnace ....................................................................... 2926
10.1. Creating a New Problem ...................................................................................... 2926
10.2. Setting Simulation Controls .................................................................................. 2926
10.3. Creating Billet Geometry ...................................................................................... 2927
10.4. Meshing the Billet ................................................................................................. 2928
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Table of Contents
10.5. Defining Billet Heat Transfer Boundary Conditions .............................................. 2928

10.6. Importing Billet Material ........................................................................................ 2928
10.7. Saving the Problem and Running the Simulation ................................................. 2930
10.8. Post-Processing ................................................................................................... 2930
Lab 11. Restarting Heat Transfer ............................................................................................... 2933
11.1. Opening a Previous Simulation ............................................................................ 2933
11.2. Revisiting Simulation Controls .............................................................................. 2934
11.3. Revisiting Boundary Conditions ........................................................................... 2934
11.4. Writing the Database and Continuing the Simulation ........................................... 2935
11.5. Post-Processing ................................................................................................... 2935
Lab 12. Spike Forging - Non-Isothermal ..................................................................................... 2940
12.2. Setting Simulation Controls ................................................................................. 2940
12.3. Importing Materials ............................................................................................... 2941
12.4. Setting Object Data .............................................................................................. 2941
12.5. Object Positioning ................................................................................................. 2942
12.6. Inter-Object Relationships ................................................................................... 2942
12.7. Writing the Database and Running the Simulation .............................................. 2942
12.8. Post-Processing ................................................................................................... 2942
Lab 13. CHANGING DIES - SPIKE FORGING ........................................................................... 2946
13.2. Loading Step from the Previous Database........................................................... 2946
13.3. Creating New Die Geometry (Flat Top Die) ......................................................... 2946
13.4. Positioning New Top Die ...................................................................................... 2947
13.5. Defining Self Contact for the Billet ........................................................................ 2947
13.6. Modifying Billet Mesh Settings ............................................................................. 2947
13.7. Defining New Contact Boundary Conditions ........................................................ 2947
13.8. Initializing Stroke for Primary Die ........................................................................ 2947
13.9. Redefining Simulation Input ................................................................................. 2948
13.10. Writing the Database ................................................................................................ 2948
13.11. Running the Simulation ............................................................................................ 2948
13.12. Post-processing the Results ..................................................................................... 2948
13.13. Exiting DEFORM-2D/3D ........................................................................................... 2949
Lab 14. HAMMER FORGING SIMULATION – SPIKE FORGING (ISOTHERMAL) ................... 2952
14.1. Creating a new problem ....................................................................................... 2952
14.2. Importing Spike Forging (Isothermal) .................................................................. 2952
14.3. Importing Material ................................................................................................ 2952
14.4. Defining Movement Control for Hammer Forging ................................................ 2952
14.5. Writing the Database ............................................................................................ 2953
14.6. Running the Simulation ........................................................................................ 2953
14.7. Post-processing the Results ................................................................................. 2953
14.8. Continuing the Simulation..................................................................................... 2954
14.9. Exiting DEFORM-2D/3D ....................................................................................... 2954
Lab 15. SCREW PRESS SIMULATION - Spike Forging (Isothermal) ........................................ 2956
xxxv
15.2. Importing Spike Forging (Isothermal) ................................................................... 2956

15.3. Importing Material ................................................................................................. 2956
15.4. Defining Movement Control for Screw Press ....................................................... 2956
Lab 16. DIE STRESS ANALYSIS - Multiple Dies (NON -ISOTHERMAL) .................................. 2960
16.2. Importing Spike Forging (Non-Isothermal) ........................................................... 2961
16.4. Defining BCC’s ..................................................................................................... 2961
16.5. Checking Material Data - Elastic Properties ......................................................... 2962
Lab 17. DIE STRESS ANALYSIS - MULTIPLE DIES (NON-ISOTHERMAL)............................. 2965
17.1. Opening an Existing Problem ............................................................................... 2965
17.2. Creating a New Object ......................................................................................... 2965
17.3. Defining BCC’s ..................................................................................................... 2966
17.4. Defining Poisson’s Ratio and Young’s Modulus ................................................... 2966
17.5. Assigning Inter-Object Relations .......................................................................... 2966
17.6. Generating Inter-Object BCC’s ............................................................................. 2966
Lab18. DIE STRESS ANALYSIS - SHRINK FIT (NON-ISOTHERMAL)................................... 2969
18.3. Defining BCC’s ..................................................................................................... 2970
18.4. Selecting a Material .............................................................................................. 2970
Lab 19. 2D SIMULATION OF SLAB ROLLING .......................................................................... 2973
19.3. Creating Object #1 ................................................................................................ 2973
19.4. Creating Object #2 ................................................................................................ 2974
19.5. Setting Inter-Object Properties ............................................................................. 2974
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Table of Contents

Lab 20. MECHANICAL PRESS SIMULATION - SPIKE FORGING (ISOTHERMAL) ................ 2977
20.3. Changing Movement Control ................................................................................ 2978
Lab 21. HYDRAULIC PRESS SIMULATION - SPIKE FORGING (ISOTHERMAL) ................... 2980
21.3. Defining Movement Control for Hydraulic Press .................................................. 2981
Lab 22. FORMING OF A ROLLER BEARING RACE USING A POROUS MATERIAL ............. 2984
22.2. Importing and Checking Geometry....................................................................... 2984
22.3. Defining Properties of Object #1 .......................................................................... 2984
22.4. Assigning Movement to Object #2 ........................................................................ 2985
22.5. Assigning Inter-Object Properties ........................................................................ 2985
22.6. Checking Object Positioning ................................................................................ 2986
22.11. Post-Processing the Results .................................................................................... 2986
Lab 23. 2D HAMMER MULTIPLE OPERATIONS ...................................................................... 2989
23.1. Create a regular hammer problem ....................................................................... 2990
23.2. Define multiple operations .................................................................................... 2990
23.3. Submit simulation ................................................................................................. 2992
Lab 24. 2D ROLLING MULTIPLE OPERATIONS ...................................................................... 2994
24.1. Create a regular rolling problem ........................................................................... 2994
24.4. Continuing Simulation........................................................................................... 2997
Lab 25. 2D STUB SHAFT LAB .................................................................................................. 3000
25.1. Create Geometry .................................................................................................. 3001
xxxvii
25.2. Mesh Generation. ................................................................................................. 3008

25.3. Finishing Data Preparation ................................................................................... 3012
25.4. Running a simulation ............................................................................................ 3018
25.5. Postprocessing the operation ............................................................................... 3019
25.6. Running a second operation ................................................................................ 3021
25.7. Postprocessing ..................................................................................................... 3024
25.8. Tool Stress Analysis ............................................................................................. 3026
25.9. Simulating thermal effects .................................................................................... 3029
25.10. Warm Stub shaft with Mechanical Press movement ................................................ 3033
25.11. Warm Stub shaft with Hydraulic Press movement ................................................... 3034
25.12. Warm Stub shaft with Screw press movement......................................................... 3035
25.13. Warm Stub shaft with Hammer movement.............................................................. 3035
F2 Wizard Labs ................................................................................................................................ 3037
Lab 1. F2 Cold Forming Labs ....................................................................................................... 3037
1.1. Create a New Problem. Import and Manipulate Workpiece ......................................... 3037
1.2. Import tools – Manipulate Object Display ..................................................................... 3039
1.3. Bad Geometry and Geometry Repair ........................................................................... 3040
1.4. Generate Mesh ............................................................................................................. 3042
1.5. Completing Pre Processing .......................................................................................... 3043
1.6. Run Simulation and Postprocess ................................................................................. 3045
1.7. Restart Operation 2 ...................................................................................................... 3046
1.9. Die Stress .................................................................................................................... 3049
Cutting Wizard Labs......................................................................................................................... 3053
Machining Cutting Lab1 ............................................................................................................... 3053
Heat Treatment Labs ....................................................................................................................... 3055
1. Modeling of a Heating Operation with Phase Transformation. ............................................... 3055
1.3. Loading the Material Properties ................................................................................... 3057
1.4. Creating Object #1 ........................................................................................................ 3057
1.5. Creating Object #2 ........................................................................................................ 3060
1.6. Defining Inter-Object Relations..................................................................................... 3060
1.8. Running a Simulation ................................................................................................... 3062
2. Modeling of Carburization of a Gear Tooth ............................................................................. 3064
2.3. Setting Boundary Conditions ........................................................................................ 3065
3. Modeling of Diffusion of a Gear Tooth .................................................................................... 3068
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Table of Contents

4. Modeling of Quenching of a Gear Tooth ................................................................................. 3072
4.3. Setting Object Properties .............................................................................................. 3073
5. PREPARING MATERIAL AND PHASE TRANSFORMATION DATA .................................... 3077
5.1. The Basic Concepts ..................................................................................................... 3077
5.3. Setting Units ................................................................................................................. 3080
5.4. Setting Material Properties ........................................................................................... 3080
5.5. Setting Inter-Material Properties ................................................................................... 3081
5.6. Saving Materials ........................................................................................................... 3085
6. Grain Modeling ........................................................................................................................ 3087
6.1. Introduction ................................................................................................................... 3087
6.2. Load Deformation Keyword File ................................................................................... 3088
6.3. Specify Grain-related Material Data ............................................................................. 3088
6.4. Input Initial Grain Variables .......................................................................................... 3089
6.5. Run Deformation Simulation......................................................................................... 3090
6.6. Prepare and Run Air-cooling Simulation ...................................................................... 3090
6.7. Prepare and Run Water-Quenching Simulation ........................................................... 3090
6.8. Post Processing ............................................................................................................ 3091
6.9. Changing Conditions .................................................................................................... 3093
Inverse Heat Wizard Labs ............................................................................................................... 3097
Inverse Heat Wizard Lab1 ............................................................................................................ 3097
Inv Heat Wizard Lab2 ................................................................................................................... 3099
Tool Wear Labs ................................................................................................................................ 3101
Tool Wear Lab .............................................................................................................................. 3101
Resistance Heating Labs ................................................................................................................. 3103
Resistance Heating Lab ............................................................................................................... 3103
13 2D Labs MO ................................................................................................................................... 3105
2D MO Labs Index ........................................................................................................................... 3105
MO Basic Labs ................................................................................................................................. 3108
Lab 01 Geometry Manipulation and Uniform mesh ..................................................................... 3108
1.1. Creating a New problem ............................................................................................... 3108
1.2. Adding Forming operation ............................................................................................ 3111
1.3. Selecting Geometry Type ............................................................................................. 3112
1.4. Adding Objects ............................................................................................................. 3113
1.5. Workpiece ..................................................................................................................... 3114
1.6. Creating Workpiece geometry ...................................................................................... 3115
xxxix
1.7. Workpiece mesh page .................................................................................................. 3119

Lab02. Geometry Correction ........................................................................................................ 3123
2.1. Geometry Type ............................................................................................................. 3127
2.2. Adding Object ............................................................................................................... 3127
2.3. Geometry Editing .......................................................................................................... 3128
Lab 03 Spike Isothermal .............................................................................................................. 3134
3.2. Adding Forming operation - Spike ................................................................................ 3137
3.3. Spike Isothermal- Block ................................................................................................ 3173
3.4. Close MO Wizard ......................................................................................................... 3186
Lab 04 Heat Transfer ................................................................................................................... 3188
4.2. Adding Heating Express operation ............................................................................... 3191
4.3. Changing operation Name............................................................................................ 3192
4.4. Heating in Furnace ....................................................................................................... 3193
4.5. Heating Furnace Process setup ................................................................................... 3193
4.6. Workpiece Setup .......................................................................................................... 3194
4.7. Furnace Heat Condition Setup ..................................................................................... 3198
4.8. Heating Furnace Simulation controls ........................................................................... 3199
4.9. DB Generation for Heating Furnace ............................................................................. 3200
4.10. Air cool operation .................................................................................................. 3201
4.11. Air cooling Heat Condition Setup ......................................................................... 3201
4.12. Simulation Controls For Air cooling ...................................................................... 3201
4.13. DB Generation For Air Cooling ............................................................................. 3202
4.14. Starting the Simulation ......................................................................................... 3202
4.15. Post-Processing the Results ................................................................................ 3203
Lab 05 Spike Non-Isothermal ....................................................................................................... 3209
5.2. Adding Operation .......................................................................................................... 3213
5.3. Geometry type selection ............................................................................................... 3214
5.4. Loading Materials of Workpiece and Dies .................................................................... 3215
5.5. Adding Objects ............................................................................................................. 3218
5.6. Workpiece Setup .......................................................................................................... 3219
5.7. Top Die Setup ............................................................................................................... 3228
5.8. Bottom Die Setup ......................................................................................................... 3233
5.9. Controls ........................................................................................................................ 3237
5.10. Contact ................................................................................................................. 3238
5.11. Simulation Controls .............................................................................................. 3241
5.12. Generating Database ........................................................................................... 3244
Lab 06 Die Stress ......................................................................................................................... 3253
6.1. Introduction ................................................................................................................... 3253
6.2. Opening project file ....................................................................................................... 3253
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Table of Contents
6.3. Add Die stress study ..................................................................................................... 3254

6.4. Step selection ............................................................................................................... 3255
6.5. Top Die Setup ............................................................................................................... 3256
6.6. Bottom Die Setup ......................................................................................................... 3258
6.7. Simulation controls Setup ............................................................................................. 3260
6.8. Generate Database ...................................................................................................... 3260
6.9. Starting the simulation .................................................................................................. 3260
6.10. Post processing the results .................................................................................. 3261
Lab 07 Mechanical Press ............................................................................................................. 3265
7.3. Import Database ........................................................................................................... 3267
7.4. Assigning Top Die Movement....................................................................................... 3268
7.6. Starting the Simulation ................................................................................................. 3270
Lab 08 Hammer Press ................................................................................................................. 3274
8.3. Importing Database ...................................................................................................... 3275
8.4. Material List .................................................................................................................. 3276
8.5. Assigning Temperature for Billet .................................................................................. 3277
8.6. Assigning Hammer Movement for Top Die .................................................................. 3278
8.7. Generating 1st Operation Database ............................................................................. 3279
8.8. Simulating 1st Operation .............................................................................................. 3280
8.9. Post-Processing the 1st operation Results .................................................................. 3280
8.10. Adding 2nd operation ........................................................................................... 3282
8.11. Adding objects ...................................................................................................... 3282
8.12. Workpiece Setup in 2nd operation ....................................................................... 3282
8.13. Top Die Setup in 2nd operation ............................................................................ 3283
8.14. Bottom Die Setup in 2nd operation ...................................................................... 3283
8.15. Generate Inter-object Contacts ............................................................................ 3284
8.17. Generating 2nd operation Database .................................................................... 3286
8.18. Simulating 2nd operation ...................................................................................... 3286
8.19. Post-Processing the 2nd Operation Results ........................................................ 3287
8.20. Closing MO Wizard ............................................................................................... 3288
Lab 09 Hammer Multiple Operation ............................................................................................. 3290
9.3. Importing Keyfile ........................................................................................................... 3292
9.4. Editing Blow table ......................................................................................................... 3292
9.5. Generating Inter-object Contact ................................................................................... 3293
9.6. Generating Database ................................................................................................... 3294
xli
Lab 10 Hydraulic press................................................................................................................. 3297

10.2. Adding Operation .................................................................................................. 3298
10.3. Importing Database .............................................................................................. 3298
10.4. Assigning Hydraulic movement for Top Die ......................................................... 3300
Lab 11 Screw press...................................................................................................................... 3305
11.4. Material List .......................................................................................................... 3307
11.5. Assigning Temperature for Billet .......................................................................... 3307
11.6. Assigning Screw press movement for Top Die .................................................... 3308
Lab 12 Die Stress with Holder ...................................................................................................... 3313
12.1. Opening Project File ............................................................................................. 3313
12.2. Add Die stress study............................................................................................. 3314
12.3. Step selection ....................................................................................................... 3314
12.4. Add Object ............................................................................................................ 3315
12.5. Top Die Setup ....................................................................................................... 3316
12.6. Bottom Die Setup ................................................................................................. 3318
12.7. Holder ................................................................................................................... 3320
12.8. Generating Inter-object Contact ........................................................................... 3324
12.9. Simulation controls ............................................................................................... 3325
12.10. Generating Database ............................................................................................... 3326
12.11. Starting the simulation .............................................................................................. 3326
12.12. Post processing the results ...................................................................................... 3326
Lab 13 Die Stress with Shrink Fit ................................................................................................. 3331
13.3. Step selection ....................................................................................................... 3333
13.4. Add Objects .......................................................................................................... 3334
13.5. Top Die Setup ....................................................................................................... 3335
13.6. Bottom Die Setup ................................................................................................. 3337
13.7. Holder Setup ......................................................................................................... 3339
13.8. Ring Setup ............................................................................................................ 3343
13.10. Simulation controls ................................................................................................... 3348
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Table of Contents
2D_DOE_lab .................................................................................................................................... 3354

1. 2D DOE Lab1 ........................................................................................................................... 3354
1.1. Nominal Project setup and simulation .......................................................................... 3354
1.2. Check and define the Nominal Project ......................................................................... 3357
1.3. Add DOE Project .......................................................................................................... 3363
1.4. Add die geometry variation as DOE variable ............................................................... 3365
1.5. Add Friction coefficient as DOE variable ...................................................................... 3375
1.6. Check DOE table .......................................................................................................... 3379
1.7. DOE Samples definition ............................................................................................... 3380
1.8. Define DOE Output operation....................................................................................... 3380
1.9. Simulate DOE project ................................................................................................... 3387
1.10. Review the DOE results ....................................................................................... 3391
2D_Machining_Distortion_lab .......................................................................................................... 3400
1. 2D Machining Distortion Lab1 ................................................................................................. 3400
1.2. Adding operation: ......................................................................................................... 3402
1.3. Object window: ............................................................................................................. 3403
1.4. Workpiece: .................................................................................................................... 3404
1.5. Setting up the fixtures: .................................................................................................. 3407
1.6. Defining the initial machining pass: .............................................................................. 3409
1.7. Controls window: .......................................................................................................... 3411
1.8. Scheduled Positioning .................................................................................................. 3412
1.9. Contact: ........................................................................................................................ 3412
1.10. Simulation Preview ............................................................................................... 3413
1.11. Simulation control ................................................................................................. 3415
1.12. DB generation: ...................................................................................................... 3415
1.13. Starting the Simulation: ........................................................................................ 3416
1.14. Post processing the results: ................................................................................. 3416
• Basic 3D Integrated Labs .................................................................................................... 3418
• F3 Wizard Labs ................................................................................................................... 3418
• Shape Rolling Wizard labs .................................................................................................. 3418
• Ring Rolling Wizard labs ..................................................................................................... 3418
• Extrusion Wizards Labs ...................................................................................................... 3419
• 3D Cutting Labs................................................................................................................... 3419
• Tool Wear Labs ................................................................................................................... 3419
Extrusion Wizards Labs ................................................................................................................... 3421
ALE Extrusion Example1 ............................................................................................................. 3421
Basic Labs ....................................................................................................................................... 3428
Lab 1. Block Pre-Processing ................................................................................................. 3428
xliii

1.3. Loading Object Data ..................................................................................................... 3434
1.4. Display Manipulation and point selection ..................................................................... 3435
1.5. Other DISPLAY Window Icons ..................................................................................... 3435
1.7. Exiting DEFORM-2D/3D ............................................................................................... 3436
Lab 2. Block Die Positioning ................................................................................................ 3438
2.1. Introduction ................................................................................................................... 3438
2.3. Importing Dies............................................................................................................... 3439
2.4. Setting Die Movement .................................................................................................. 3441
2.8. Object Positioning ......................................................................................................... 3445
2.9. Inter-Object Relationships ............................................................................................ 3451
2.10. Generating a Database ........................................................................................ 3453
2.11. Saving the Problem .............................................................................................. 3454
Lab 3. BLOCK FORGING SIMULATION & POST-PROCESSING ...................................... 3456
3.1. Introduction ................................................................................................................... 3456
Lab 4. Square Ring ............................................................................................................... 3467
4.1. Introduction ................................................................................................................... 3468
4.4. Meshing the Billet ......................................................................................................... 3469
4.5. Setting Symmetry Boundary Conditions ....................................................................... 3469
4.7. Finishing Setup and Running Simulation ..................................................................... 3473
4.8. Post Processing ............................................................................................................ 3473
Lab 5. SPIKE FORGING -TRANSFER FROM FURNACE TO DIES ................................... 3477
5.1. Introduction ................................................................................................................... 3477
5.4. Inserting New Objects .................................................................................................. 3478
5.6. Defining Billet Heat Transfer Boundary Conditions ...................................................... 3481
5.7. Importing Billet Material ................................................................................................ 3482
5.8. Saving the Problem and Running the Simulation ......................................................... 3483
5.9. Post-Processing ........................................................................................................... 3483
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Table of Contents
Lab 6. SPIKE FORGING - DWELL ON BOTTOM DIE ......................................................... 3489

6.1. Introduction ................................................................................................................... 3489
6.3. Die Meshing and Thermal Boundary Conditions .......................................................... 3491
6.4. Importing Die Material .................................................................................................. 3493
6.5. Billet Positioning ........................................................................................................... 3494
6.9. Post-Processing ........................................................................................................... 3497
Lab 7. SPIKE FORGING - FORGING BLOW 1 .................................................................... 3501
7.1. Introduction ................................................................................................................... 3501
7.4. Positioning the Top Die ................................................................................................ 3502
7.7. Revisiting Inter-Object Relations .................................................................................. 3504
7.9. Post-Processing ........................................................................................................... 3505
Lab 8. SPIKE FORGING - DIE CHANGE AND BLOW 2 ...................................................... 3509
8.1. Introduction ................................................................................................................... 3509
8.3. Changing Top Die for Blow 2........................................................................................ 3510
8.4. Defining New Top Die Boundary Conditions ................................................................ 3510
8.6. Redefining Inter-Object Contact ................................................................................... 3511
8.9. Post-Processing ........................................................................................................... 3512
Lab 9. Die Stress Analysis .................................................................................................... 3515
9.1. Introduction ................................................................................................................... 3515
9.3. Loading a Database Step ............................................................................................. 3516
9.5. Adding Additional Tools and Deleting the Billet............................................................ 3516
9.6. Defining Inter-Object Relationships .............................................................................. 3521
9.8. Post-Processing ........................................................................................................... 3522
Lab 10. STEERING LINK ............................................................................................................ 3527
10.1. Introduction ........................................................................................................... 3527
10.3. Loading Object Geometry..................................................................................... 3529
10.4. Defining Workpiece Mesh..................................................................................... 3529
10.5. Assigning Object Temperature ............................................................................. 3530
xlv
10.6. Activating Volume Compensation ........................................................................ 3530

10.7. Assigning Movement Controls .............................................................................. 3531
10.8. Assigning Boundary Conditions ........................................................................... 3531
10.9. Assigning Stopping Controls ................................................................................ 3531
10.10. Assigning Step Controls ........................................................................................... 3532
10.11. Importing Material Data ............................................................................................ 3532
10.12. Assigning Inter-Object Boundary Conditions ............................................................ 3532
10.13. Writing the Database and Running the Simulation .................................................. 3532
10.14. Viewing and Comparing Results .............................................................................. 3533
10.15. Running a Hammer Simulation................................................................................. 3534
Lab 11. Gear Carrier ................................................................................................................... 3537
11.1. Introduction ........................................................................................................... 3537
11.2. Planning the Simulation ........................................................................................ 3538
11.6. Defining Billet Boundary Conditions ..................................................................... 3540
11.7. Defining Billet Temperature .................................................................................. 3540
11.8. Loading Material Data .......................................................................................... 3540
11.9. Setting Top Die Movement ................................................................................... 3540
11.10. Assigning Simulation Controls .................................................................................. 3541
11.11. Running the Furnace Transfer Operation ................................................................. 3541
11.12. Running the Dwell Operation.................................................................................... 3541
11.13. Running the Upset Operation ................................................................................... 3542
11.14. Running the Transfer Operation ............................................................................... 3543
11.15. Running the Second Forming Operation .................................................................. 3543
Lab 12. Hot Forming Lab - Tee Billet .......................................................................................... 3546
12.1. Create a New Problem. Import and Manipulate Geometry ................................. 3546
12.2. Import Tools – Manipulate Object Display............................................................ 3547
12.3. Bad Geometry & Geometry Repair ...................................................................... 3547
12.4. Mesh Generation .................................................................................................. 3549
12.5. Completing Pre Processing .................................................................................. 3550
12.6. Run Simulation and Postprocessor ...................................................................... 3552
12.7. Restarting Simulation ........................................................................................... 3553
12.8. Simulating Temperature Effects ........................................................................... 3555
12.9. Symmetry.............................................................................................................. 3557
12.10. Die stress .................................................................................................................. 3559
Lab 13. Stub shaft Lab ................................................................................................................ 3561
13.1. Create a New Problem. Import Geometry ............................................................ 3561
13.2. Bad Geometry and Geometry Repair ................................................................... 3562
13.3. Mesh Generation. Tool Geometry Input. .............................................................. 3562
13.5. Running a Simulation ........................................................................................... 3575
13.6. Postprocessing ..................................................................................................... 3575
13.7. Running a Second Operation ............................................................................... 3578
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Table of Contents
13.8. Postprocessing ..................................................................................................... 3581

13.9. Symmetry / Thermal Operations .......................................................................... 3587
13.10. Tool Stress Analysis ................................................................................................. 3600
13.11. Mechanical Press ..................................................................................................... 3602
Machining Labs ................................................................................................................................ 3607
Turning lab1 ................................................................................................................................. 3607
Drilling lab1 ................................................................................................................................... 3609
Machining Wizard turning Lab1 .................................................................................................... 3611
Ring Rolling Wizard labs .................................................................................................................. 3613
Ring Rolling Lab1 ......................................................................................................................... 3613
Ring Rolling Lab2 ......................................................................................................................... 3615
Ring Rolling Lab3 ......................................................................................................................... 3617
Ring Rolling Lab4 ......................................................................................................................... 3619
Shape Rolling Wizard labs ............................................................................................................... 3621
ALE Lab1 ...................................................................................................................................... 3621
Lagrangian Lab ............................................................................................................................ 3623
Tool Wear Lab ................................................................................................................................. 3625
Tool Wear Lab1 ............................................................................................................................ 3625
Inverse Heat lab ............................................................................................................................... 3627
15 3D Labs MO ................................................................................................................................... 3629
3D MO Labs Index ........................................................................................................................... 3629
• Die Stress Labs ................................................................................................................... 3629
• Tool Wear Labs ................................................................................................................... 3629
Basic labs in MO .............................................................................................................................. 3631
Lab 1. Block .................................................................................................................................. 3631
1.2. Setting material properties ............................................................................................ 3636
1.4. Controls ........................................................................................................................ 3644
1.6. Setting Simulation controls ........................................................................................... 3653
1.10. Step Tools and Step Selection ............................................................................. 3656
1.11. State Variables ..................................................................................................... 3656
1.12. Point Tracking ....................................................................................................... 3657
1.13. Slicing Objects ...................................................................................................... 3659
1.14. Exiting MO Wizard ................................................................................................ 3661
Lab 2. Square Ring ...................................................................................................................... 3663
2.1. Introduction ................................................................................................................... 3663
2.3. Adding Objects ............................................................................................................. 3669
xlvii
2.4. Creating Workpiece Object........................................................................................... 3670

2.5. Loading Workpiece Geometry ...................................................................................... 3671
2.7. Assigning Material to the Billet ..................................................................................... 3673
2.8. Setting symmetry boundary conditions ........................................................................ 3674
2.9. Creating Top die Object................................................................................................ 3676
2.10. Loading Top die Geometry ................................................................................... 3677
2.11. Assigning Movement to Top die ........................................................................... 3677
2.12. Inter-Object relationships...................................................................................... 3678
2.13. Finish the setup and running the simulation ......................................................... 3680
2.14. Running Simulation .............................................................................................. 3683
2.15. Post Processing .................................................................................................... 3684
Lab 3. Spike Forging ............................................................................................................. 3689
3.1. Spike Forging - Transfer from Furnace to Dies ............................................................ 3689
3.2. Spike Forging - Dwell On Bottom Die ........................................................................... 3704
3.3. Spike Forging - Forging Blow1 ..................................................................................... 3721
3.4. Spike Forging - Die Change and Blow2 ....................................................................... 3736
Lab 4. Steering Link .............................................................................................................. 3743
4.1. Introduction ................................................................................................................... 3743
4.2. Creating New Problem ................................................................................................. 3743
4.3. Adding operation and Objects ...................................................................................... 3744
4.4. Defining Workpiece ..................................................................................................... 3744
4.5. Defining Top Die ........................................................................................................... 3751
4.6. Defining Bottom Die ...................................................................................................... 3753
4.7. Positioning Objects ....................................................................................................... 3754
4.8. Assigning Inter-Object Boundary Conditions ................................................................ 3755
4.9. Assigning Stopping Controls ........................................................................................ 3757
4.11. Data Base Generation .......................................................................................... 3760
4.12. Post processing .................................................................................................... 3760
Forming Express Labs ..................................................................................................................... 3764
Tee Non Isothermal Forging operation ........................................................................................ 3764
Hot Forming Labs ......................................................................................................................... 3787
Creating a New Problem .......................................................................................................... 3787
Lab1- Bolt Forming ....................................................................................................................... 3818
Die Stress Labs ................................................................................................................................ 3855
Die Stress wizard lab1.................................................................................................................. 3855
2. Die Stress wizard Lab2 ........................................................................................................... 3856
2.1. Introduction ................................................................................................................... 3856
2.3. Add Die Stress Study ................................................................................................... 3857
2.4. Adding Objects ............................................................................................................. 3858
2.5. Top Die ......................................................................................................................... 3859
2.6. Bottom Die .................................................................................................................... 3863
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Table of Contents
2.7. Upper Support .............................................................................................................. 3864

2.8. Lower Support .............................................................................................................. 3869
2.11. Generate Database .............................................................................................. 3873
2.12. Post Processing .................................................................................................... 3873
Report Generation Lab in MO .......................................................................................................... 3877
1. Report Generation Lab in MO .................................................................................................. 3877
1.1. Report generation in Batch post mode ........................................................................ 3877
Machining Distortion Lab ................................................................................................................. 3937
1.3. Object window: ............................................................................................................. 3940
1.4. Workpiece: .................................................................................................................... 3941
1.7. Controls window: .......................................................................................................... 3947
1.9. Contact: ........................................................................................................................ 3948
1.12. DB generation: ...................................................................................................... 3951
Heat Treatment labs ........................................................................................................................ 3954
Lab 1. 3D Heat Treatment Wizard Lab ........................................................................................ 3954
1.1. Introduction ................................................................................................................... 3954
1.2. Starting a New problem ................................................................................................ 3954
1.3. Process Settings ........................................................................................................... 3957
1.4. Material definition ......................................................................................................... 3958
1.5. Workpiece Object Type ................................................................................................ 3959
1.6. Workpiece initialization ................................................................................................. 3965
1.7. Medium Definition ......................................................................................................... 3967
1.8. Scheduled Definition ..................................................................................................... 3970
1.9. Simulation controls ....................................................................................................... 3971
1.12. Post processing .................................................................................................... 3974
16 MO Advanced labs ......................................................................................................................... 3977
Gear Blank ....................................................................................................................................... 3978
MO Advanced Labs : Gear Blank (ENG) ..................................................................................... 3978
Lab 1. 2D upset operation .................................................................................................... 3978
Lab 2. 2D to 3D Conversion to sequence 3D operation after 2D operation ......................... 4010
Lab 3. Sequential 3D forge operation ................................................................................... 4015
xlix
Lab 4. 3D Non-isothermal Air transfer operation .................................................................. 4030

Lab 5. 3D Non-isothermal Forming operation ...................................................................... 4039
Lab 6. Mechanical Press ...................................................................................................... 4054
Lab 7. Hammer ..................................................................................................................... 4059
Lab 8. Screw Press............................................................................................................... 4066
Lab 9. Hydraulic Press ......................................................................................................... 4071
Lab 10. Gear Blank Symmetry Operation ...................................................................... 4078
Lab 11. Interpreting Results ........................................................................................... 4083
Lab 12. Die Stress analysis - Hot Forging ...................................................................... 4085
MO Advanced Labs : Gear Blank (SI) .......................................................................................... 4102
Lab 7. Hammer ..................................................................................................................... 4182
Lab 8. Screw Press............................................................................................................... 4189
l
Table of Contents
1 Introduction to DEFORM ............................................................................................................................ 3
1.1. Overview of DEFORM ....................................................................................................................... 4
1.2. DEFORM family of products .............................................................................................................. 7
1.2.1. BASE PRODUCTS .............................................................................................................. 8
1.2.2. SUPPORT MODULES ......................................................................................................... 9
1.2.3. ADD-ON Modules .............................................................................................................. 11
1.3. Capabilities ...................................................................................................................................... 14
1.3.1. Deformation ....................................................................................................................... 14
1.3.2. Heat Treatment .................................................................................................................. 15
1.4. Analyzing manufacturing processes with DEFORM ....................................................................... 19
1.5. Before you begin ............................................................................................................................. 22
1.6. The DEFORM system ..................................................................................................................... 24
1.6.1. Pre-processing ................................................................................................................... 24
1.6.2. Running the simulation ...................................................................................................... 25
1.6.3. Post-processor ................................................................................................................... 26
1.7. Geometry representation ................................................................................................................. 28
1.8. Creating input data .......................................................................................................................... 31
1.9. Units................................................................................................................................................. 34
1.10. File system ................................................................................................................................. 37
1.11. Release Notes - V11.0 (PC) ....................................................................................................... 40
2 Integrated Pre Processor ......................................................................................................................... 53
2.1. GUI Main and Pre-processor Layout ............................................................................................... 54
2.1.1. Integrated GUI Interference ............................................................................................... 54
2.1.1.1. File Menu.................................................................................................................... 57
2.1.1.2. Simulation Menu ........................................................................................................ 60
2.1.1.3. Tool Menu .................................................................................................................. 61
2.1.1.3.1. DB Manager ............................................................................................................... 61
2.1.1.4. View............................................................................................................................ 63
2.1.1.5. Options ....................................................................................................................... 64
2.1.1.6. Help ............................................................................................................................ 64
2.1.2. Pre-Processor Layout ........................................................................................................ 66
2.1.3. Graphic Utilities .................................................................................................................. 67
2.1.3.1. File.............................................................................................................................. 67
2.1.3.2. Input ........................................................................................................................... 69
2.1.3.2.1. Simulation controls ..................................................................................................... 69
2.1.3.2.2. Material ....................................................................................................................... 69
2.1.3.2.3. Object positioning ....................................................................................................... 69
2.1.3.2.4. Inter Object ................................................................................................................. 70
2.1.3.2.5. Database .................................................................................................................... 70
2.1.3.2.6. Convert 2D to 3D ........................................................................................................ 70
2.1.3.2.7. Object Node ................................................................................................................ 70
2.1.3.2.8. Object Elements ......................................................................................................... 70
iii
2.1.3.2.9. Object Edges .............................................................................................................. 70

2.1.3.2.10. Boolean Operation............................................................................................ 71
2.1.3.2.11. Data Interpolation ............................................................................................. 71
2.1.3.3. Viewport ..................................................................................................................... 72
2.1.3.3.1. Refresh (F5) ............................................................................................................... 72
2.1.3.3.2. View Fit (F3) ............................................................................................................... 72
2.1.3.3.3. View back (F4) ........................................................................................................... 72
2.1.3.3.4. Auto Fit ....................................................................................................................... 72
2.1.3.3.5. Load and Save ........................................................................................................... 72
2.1.3.4. Display........................................................................................................................ 74
2.1.3.4.1. Measure ...................................................................................................................... 74
2.1.3.4.2. Select .......................................................................................................................... 75
2.1.3.4.3. Pan (Shift+LMB) ........................................................................................................ 75
2.1.3.4.4. Dynamic zoom (Alt+LMB) .......................................................................................... 75
2.1.3.4.5. Box Zoom Window (Ctrl+Alt+LMB) ........................................................................... 75
2.1.3.4.6. Rotate (Ctrl+LMB)...................................................................................................... 76
2.1.3.4.7. Rotate X ...................................................................................................................... 76
2.1.3.4.8. Rotate Y ...................................................................................................................... 76
2.1.3.4.9. Rotate Z ...................................................................................................................... 76
2.1.3.4.10. Isometric View .................................................................................................. 76
2.1.3.4.11. Viewpoint .......................................................................................................... 76
2.1.3.4.12. Screen Upward ................................................................................................. 77
2.1.3.4.13. Show Model ...................................................................................................... 77
2.1.3.5. Model.......................................................................................................................... 78
2.1.3.6. Tools........................................................................................................................... 78
2.1.3.7. View............................................................................................................................ 79
2.1.3.8. Options ....................................................................................................................... 79
2.1.3.8.1. Environment ............................................................................................................... 79
2.1.3.8.2. Preferences ................................................................................................................ 88
2.1.3.8.3. Display properties ....................................................................................................... 91
2.1.3.8.4. Graph properties ......................................................................................................... 92
2.1.3.8.5. Save current settings .................................................................................................. 92
2.1.3.9. Help: ........................................................................................................................... 93
2.1.3.10. Axis Tools: ..................................................................................................................... 93
2.1.4. Object Display Modes ........................................................................................................ 94
2.1.5. Right Mouse Button Display Options ................................................................................. 94
2.1.5.1. Show Dimensions [2D, 3D] ........................................................................................ 95
2.1.5.2. Show Origin Axis [2D, 3D].......................................................................................... 95
2.1.5.3. Show Step Info. [2D, 3D]............................................................................................ 95
2.1.5.4. Show Ruler [2D] ......................................................................................................... 96
2.1.5.5. Show Current Object mark [2D, 3D] .......................................................................... 96
2.1.5.6. Contact Display [2D, 3D] ............................................................................................ 96
2.1.5.7. Calculate Contact Area [3D] ...................................................................................... 97
2.1.5.8. Use Object Coordinate for rotation [3D]: .................................................................... 97
2.1.5.9. Measure [2D, 3D] ....................................................................................................... 97
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2.1.5.10. Picking mode [2D, 3D] .................................................................................................. 97

2.1.5.11. Picking Sensitivity [2D, 3D] ........................................................................................... 98
2.1.5.12. Theme [2D, 3D] ............................................................................................................. 98
2.1.5.13. Set as Default [2D, 3D] ................................................................................................. 99
2.1.5.14. Change feature angle [3D] ............................................................................................ 99
2.1.5.15. Viewport information [2D, 3D] ..................................................................................... 100
2.1.5.16. Display Properties [2D, 3D] ......................................................................................... 101
2.2. Simulation Controls ....................................................................................................................... 103
2.2.1. Main controls ................................................................................................................... 104
2.2.1.1. Simulation Information ............................................................................................. 104
2.2.1.1.1. Simulation title (TITLE) [2D, 3D] ............................................................................... 104
2.2.1.1.2. Operation name (SIMNAM) [2D, 3D] ........................................................................ 104
2.2.1.1.3. Operation number (CURSIM) [2D, 3D] ..................................................................... 105
2.2.1.1.4. Mesh number (MESHNO) [2D, 3D] .......................................................................... 105
2.2.1.1.5. Geometry type (GEOTYP) [2D] ................................................................................ 105
2.2.1.2. Units (UNIT) [2D, 3D] ............................................................................................... 106
2.2.1.3. Type (STYPE) .......................................................................................................... 106
2.2.1.3.1. Lagrangian Incremental [2D, 3D] ............................................................................. 107
2.2.1.3.2. ALE Rolling [3D] ....................................................................................................... 107
2.2.1.3.3. Steady-State machining [2D, 3D] ............................................................................. 107
2.2.1.3.4. Ring Rolling [3D] ....................................................................................................... 107
2.2.1.3.5. Steady-State extrusion [3D]...................................................................................... 108
2.2.1.3.6. ALE Extrusion [3D] ................................................................................................... 108
2.2.1.4. Simulation modes (SMODE, TRANS) ...................................................................... 108
2.2.1.4.1. Heat transfer ............................................................................................................. 108
2.2.1.4.2. Deformation .............................................................................................................. 108
2.2.1.4.3. Transformation ......................................................................................................... 108
2.2.1.4.4. Diffusion .................................................................................................................... 108
2.2.1.4.5. Grain ......................................................................................................................... 108
2.2.1.4.6. Heating ..................................................................................................................... 109
2.2.2. Simulation steps .............................................................................................................. 110
2.2.2.1. Starting step number (NSTART) [2D, 3D]................................................................ 110
2.2.2.2. Number of simulation steps (NSTEP) [2D, 3D] ....................................................... 111
2.2.2.3. Step increment to save (STPINC) [2D, 3D] ............................................................ 111
2.2.2.4. Primary die (PDIE) [2D, 3D] ..................................................................................... 111
2.2.3. Step Increment ................................................................................................................ 112
2.2.3.1. Step increment control (DSMAX/DTMAX) [2D, 3D] ................................................. 113
2.2.3.2. Step definition (STPDEF) [2D, 3D] .......................................................................... 113
2.2.3.3. Selecting time step and number of steps [2D, 3D] .................................................. 113
2.2.3.4. Sub-stepping Controls.............................................................................................. 114
2.2.3.4.1. Strain per step (DEMAX) [2D, 3D] ............................................................................ 114
2.2.3.4.2. Contact Time (DTSUB) [2D, 3D] .............................................................................. 114
2.2.3.4.3. Polygon length sub step (DPLEN) [3D] .................................................................... 115
2.2.4. Advanced Step Controls .................................................................................................. 116
2.2.4.1. Temperature change per step (DTPMAX) [2D, 3D] ................................................. 117
v
2.2.4.2. Deformation time per step (DTPMAX) [2D].............................................................. 117

2.2.4.3. Maximum Sliding Error ............................................................................................. 117
2.2.4.4. Volume change per step (DVMAX) [2D] .................................................................. 118
2.2.5. Stopping Controls ............................................................................................................ 119
2.2.5.1. Process Duration (TMAX) [2D, 3D] ......................................................................... 119
2.2.5.2. Primary Die Displacement (SMAX) [2D, 3D]........................................................... 119
2.2.5.3. Minimum velocity of Primary Die (VMIN) [2D, 3D] .................................................. 120
2.2.5.4. Maximum load of Primary Die (LMAX) [2D, 3D] ...................................................... 120
2.2.5.5. Maximum strain in any Element (EMAX) [2D, 3D] ................................................... 120
2.2.5.6. Stopping distance (MDSOBJ) [2D, 3D] .................................................................... 120
2.2.5.7. Stopping Plane (REFPOS) [2D, 3D] ........................................................................ 121
2.2.5.8. Temperature stopping control [2D, 3D] .................................................................... 122
2.2.6. Remesh Criteria ............................................................................................................... 123
2.2.7. Iteration Controls ............................................................................................................. 124
2.2.7.1. Deformation solver (SOLMTD) [2D, 3D] .................................................................. 125
2.2.7.1.1. Sparse [2D] ............................................................................................................... 125
2.2.7.1.2. Skyline [2D] .............................................................................................................. 125
2.2.7.2. Iteration methods (ITRMTH) [2D, 3D] ...................................................................... 129
2.2.7.2.1. Newton-Raphson ...................................................................................................... 129
2.2.7.2.2. Direct ........................................................................................................................ 130
2.2.7.3. Convergence error limits (CVGERR) [2D, 3D] ......................................................... 130
2.2.7.4. Temperature solver (SOLMTT) [2D, 3D]................................................................. 130
2.2.7.4.1. Sparse [2D] ............................................................................................................... 130
2.2.7.4.2. Skyline [2D] .............................................................................................................. 130
2.2.7.5. Maximum number of iterations (ITRMXD, ITRMXT) [2D, 3D] .................................. 132
2.2.7.6. Bandwidth optimization (DEFBWD, TMPBWD) [2D, 3D] ......................................... 132
2.2.8. Processing Conditions ..................................................................................................... 133
2.2.8.1. Heat Transfer [2D, 3D] ............................................................................................ 133
2.2.8.1.1. Environment temperature (ENVTMP) ...................................................................... 133
2.2.8.1.2. Radiation................................................................................................................... 134
2.2.8.1.3. Convection coefficient (CNVCOF) ............................................................................ 134
2.2.8.2. Diffusion [2D, 3D] ..................................................................................................... 134
2.2.8.2.1. Environment atom content (ENVATM) [MIC] ........................................................... 134
2.2.8.2.2. Reaction rate coefficient (ACVCOF) [DIF] ................................................................ 135
2.2.8.3. Induction [2D, 3D] .................................................................................................... 135
2.2.8.3.1. Magnetic permeability (ENVMPR) ............................................................................ 135
2.2.8.3.2. Magnetic permittivity (ENVMPT) .............................................................................. 135
2.2.8.3.3. Source Energy Ratio (EHRATE) .............................................................................. 136
2.2.8.4. Constants [2D, 3D] ................................................................................................... 136
2.2.8.4.1. Interface penalty constant (PENINF) ........................................................................ 136
2.2.8.4.2. Mechanical to heat conversion (UNTE2H) ............................................................... 137
2.2.8.4.3. Time integration factor (TINTGF) ............................................................................. 137
2.2.8.4.4. Boltzmann constant (BLZMAN) ................................................................................ 137
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2.2.9. Advanced Controls .......................................................................................................... 138

2.2.9.1. Variables [2D, 3D] .................................................................................................... 138
2.2.9.1.1. Current Global Time/Current Local Time (TNOW) ................................................... 138
2.2.9.1.2. Primary Workpiece (PDIE) ....................................................................................... 139
2.2.9.1.3. Use original additive rule for transformation kinetics (TRANS) ................................ 139
2.2.9.2. Error Tolerances [2D, 3D] ........................................................................................ 139
2.2.9.2.1. Contact release method (CNTERR) [2D] ................................................................. 139
2.2.9.2.2. Geometry error (GEOERR) [2D, 3D] ........................................................................ 139
2.2.9.3. User defined variables (USRDEF) [2D, 3D] ............................................................. 141
2.2.9.4. Output Control [2D, 3D]............................................................................................ 141
2.2.9.5. Nodal Oscillations [2D] ............................................................................................. 144
2.2.9.5.1. Corner oscillations .................................................................................................... 145
2.2.9.5.2. Repeated touching / separating ............................................................................... 145
2.2.10. Control Files ......................................................................................................................... 146
2.2.10.1. Category 1 ................................................................................................................... 147
2.2.10.1.1. Double corner constraints .............................................................................. 147
2.2.10.1.2. Solver switch control....................................................................................... 147
2.2.10.2. Category 2 ................................................................................................................... 147
2.2.10.2.1. Additional remeshing criteria .......................................................................... 148
2.2.10.2.2. Body weight .................................................................................................... 148
2.2.11. Post processing Variable ..................................................................................................... 149
2.3. Material Data ................................................................................................................................. 152
2.3.1. Phases and mixtures (MSTMTR) [MIC] ........................................................................... 153
2.3.2. Plastic Data ...................................................................................................................... 158
2.3.2.1. Flow Stress (FSTRES) ............................................................................................. 158
2.3.2.1.1. Tabular data format .................................................................................................. 159
2.3.2.1.2. Power Law ................................................................................................................ 159
2.3.2.1.5. Linear hardening ....................................................................................................... 160
2.3.2.1.6. Generalized Johnson and Cook model .................................................................... 161
2.3.2.1.7. Zerilli-Armstrong model ............................................................................................ 161
2.3.2.1.8. Norton-Hoff Law model............................................................................................. 162
2.3.2.1.9. Microstructure Flow stress model based on dislocation density and burgers vector162
2.3.2.1.10. f(strn,strnrt,O,T): (This option available only in MO) ...................................... 163
2.3.2.1.11. Tabulate Data: (This option available only in MO) ......................................... 165
2.3.2.1.12. Tabulate Data (LOG): (This option available only in MO) .............................. 166
2.3.2.1.13. Bird-Mukharjee-Dorn equation: (This option available only in MO) ............... 166
2.3.2.1.14. User defined flow stress routine ..................................................................... 167
2.3.2.2. Creep (CREEP) [MIC] .............................................................................................. 171
2.3.2.2.1. Perzyna's model ....................................................................................................... 173
2.3.2.2.2. Power Law ................................................................................................................ 174
2.3.2.2.3. Baily-Norton's model................................................................................................. 174
2.3.2.2.4. Soderburg's model.................................................................................................... 174
2.3.2.2.5. Tabular data ............................................................................................................. 175
vii
2.3.2.2.6. User Routines ........................................................................................................... 177

2.3.2.3. Yield function type .................................................................................................... 178
2.3.2.3.1. Von Mises ................................................................................................................. 179
2.3.2.3.2. Hill’s quadratic (FGHLMN)........................................................................................ 179
2.3.2.3.3. Hill’s quadratic (R value)........................................................................................... 180
2.3.2.3.4. Lankford coefficient (R value) ................................................................................... 180
2.3.2.3.5. Hill’s Quadratic (polycrystalline plasticity model)...................................................... 181
2.3.2.3.6. User’s routine ........................................................................................................... 182
2.3.2.4. Hardening model (HDNRUL) [MIC] .......................................................................... 182
2.3.3. Elastic data ...................................................................................................................... 183
2.3.3.1. Young's modulus (YOUNG) ..................................................................................... 183
2.3.3.2. Poisson's ratio (POISON) ........................................................................................ 184
2.3.3.3. Thermal expansion (EXPAND) ................................................................................ 184
2.3.3.4. Material Reference Temperature (REFTMP) ........................................................... 185
2.3.4. Thermal data .................................................................................................................... 185
2.3.4.1. Thermal conductivity (THRCND) ............................................................................. 186
2.3.4.2. Heat capacity (HEATCP) ......................................................................................... 186
2.3.4.3. Emissivity (EMSVTY) ............................................................................................... 187
2.3.4.4. Density (DENSTY) ................................................................................................... 187
2.3.5. Diffusion data ................................................................................................................... 187
2.3.5.1. Diffusion coefficient (DIFCOE) ................................................................................. 188
2.3.6. Grain growth/recrystallization model ............................................................................... 190
2.3.6.1. Avrami Model: .......................................................................................................... 191
2.3.6.1.1. Dynamic Recrystallization ........................................................................................ 192
2.3.6.1.2. Static Recrystallization ............................................................................................. 193
2.3.6.1.3. Meta-dynamic Recrystallization ................................................................................ 194
2.3.6.1.4. Grain Growth ............................................................................................................ 194
2.3.6.2. Mesoscale Model ..................................................................................................... 196
2.3.7. Hardness data [MIC] ........................................................................................................ 197
2.3.7.1. Hardness of each phase (HDNPHA) ....................................................................... 198
2.3.7.2. Jominy curve (JOMINY) ........................................................................................... 198
2.3.7.3. Cooling time (HDNTIM) ............................................................................................ 198
2.3.8. Electromagnetic data ....................................................................................................... 199
2.3.9. Advanced Features .......................................................................................................... 199
2.3.9.1. Fracture Data (FRCMOD) ........................................................................................ 200
2.3.9.1.1. Normalized C&L damage model .............................................................................. 201
2.3.9.1.2. Cockroft & Latham damage model ........................................................................... 201
2.3.9.1.3. McClintock damage model ....................................................................................... 201
2.3.9.1.4. Freudenthal damage model ..................................................................................... 201
2.3.9.1.5. Rice & Tracy damage model .................................................................................... 201
2.3.9.1.6. Oyane damage model .............................................................................................. 202
2.3.9.1.7. Oyane (negative) damage model ............................................................................. 202
2.3.9.1.8. Ayada damage model............................................................................................... 202
2.3.9.1.9. Ayada (negative) damage model ............................................................................. 202
2.3.9.1.10. Osakada damage model ................................................................................ 202
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2.3.9.1.11. Brozzo damage model.................................................................................... 203

2.3.9.1.12. Zhoa & Kuhn damage model .......................................................................... 203
2.3.9.1.13. Damage based on Maximum principal stress / ultimate tensile strength ....... 203
2.3.9.1.14. Damage user routine ...................................................................................... 203
2.3.9.1.15. Void Closure: (Option available only in MO) .................................................. 204
2.3.9.1.16. FLD : (Option available only in MO) ............................................................... 205
2.3.9.2. Mechanical Work to Heat (FRAE2H) ....................................................................... 206
2.3.9.3. Force per unit volume or Body Force (FPERV) ....................................................... 207
2.3.9.4. Centrifugal force ....................................................................................................... 207
2.3.9.5. Diffusion Bonding [Available only in MO] ................................................................. 207
2.3.9.6. Size Model (SIZESH and SIZEMD) ......................................................................... 210
2.3.9.7. Sintering Driving Force model [Available only in MO] .............................................. 212
2.3.9.7.1. Simple Elastic one-step ............................................................................................ 212
2.3.9.7.2. Skorohod .................................................................................................................. 213
2.3.9.7.3. Cocks ........................................................................................................................ 214
2.3.9.7.4. Shinagawa ................................................................................................................ 215
2.3.9.7.5. Ashby ........................................................................................................................ 215
2.3.9.7.6. Raj/Ashby ................................................................................................................. 216
2.3.10. Dislocation ........................................................................................................................... 217
2.3.11. Texture ................................................................................................................................. 217
2.3.12. Material data requirements .................................................................................................. 217
2.4. Inter Material Data ......................................................................................................................... 222
2.4.1. Transformation relation (PHASTF) [MIC] ........................................................................ 222
2.4.2. Kinetics model (TTTD) [MIC] ........................................................................................... 224
2.4.2.1. Diffusion type TTT table form (Temp, Stress, Atom) ............................................... 225
2.4.2.2. Martensitic type (Tms, Tms50 Table form) .............................................................. 226
2.4.2.3. Diffusion type (function) ........................................................................................... 227
2.4.2.4. Diffusion type (function and table) ........................................................................... 229
2.4.2.5. Martensitic type (function) ........................................................................................ 230
2.4.2.6. Diffusion type (simplified) ......................................................................................... 231
2.4.2.7. MEDC ....................................................................................................................... 232
2.4.2.8. Secondary alpha lath ............................................................................................... 234
2.4.2.9. Ti-beta to grain boundary alpha ............................................................................... 236
2.4.2.10. Ti-beta to side plate alpha ........................................................................................... 238
2.4.2.11. User routine ................................................................................................................. 240
2.4.3. Latent heat (PHASLH) [MIC] ........................................................................................... 241
2.4.4. Transformation induced volume change (PHASVL) [MIC] .............................................. 242
2.4.5. Transformation plasticity (TRNSFP) [MIC] ...................................................................... 243
2.4.6. Other ................................................................................................................................ 245
2.4.6.1. Thermal Direction ..................................................................................................... 245
2.4.6.2. Equilibrium volume fraction ...................................................................................... 246
2.4.6.3. Variation selection model (option available only in MO): ......................................... 246
2.4.6.4. Interface Energy (option available only in MO): ....................................................... 246
2.4.7. Coarsening....................................................................................................................... 246
2.5. Object General Definition .............................................................................................................. 248
ix
2.5.1. Adding, deleting objects................................................................................................... 249

2.5.2. Object name (OBJNAM) .................................................................................................. 249
2.5.3. Primary Die (PDIE) .......................................................................................................... 251
2.5.4. Object type (OBJTYP) ..................................................................................................... 251
2.5.4.1. Rigid [2D, 3D] ........................................................................................................... 251
2.5.4.2. Elastic [2D, 3D] ........................................................................................................ 251
2.5.4.3. Plastic [2D, 3D] ........................................................................................................ 252
2.5.4.4. Elasto-plastic (Ela-Pla) [2D, 3D] .............................................................................. 252
2.5.4.5. Porous [2D, 3D] ........................................................................................................ 253
2.5.4.6. User [2D] .................................................................................................................. 253
2.5.5. Object material ................................................................................................................. 255
2.5.6. Object initial conditions .................................................................................................... 255
2.6. Geometry Data .............................................................................................................................. 258
2.6.1.1. Geometry Rules for 2D ............................................................................................ 259
2.6.1.2. 2D Geometry Tools .................................................................................................. 260
2.6.1.2.1. Importing Geometry [2D] .......................................................................................... 260
2.6.1.2.2. Scale Geometry [2D] ................................................................................................ 260
2.6.1.2.3. Check Geometry [2D] ............................................................................................... 261
2.6.1.2.5. Edit Boundary [2D] ................................................................................................... 262
2.6.1.2.6. Extract Border [2D] ................................................................................................... 264
2.6.1.2.7. Extract Mesh [2D] ..................................................................................................... 264
2.6.1.2.8. Primitives [2D] .......................................................................................................... 264
Show geometry inside mark [2D]................................................................................................ 268
2.6.1.3. 2D Geometry Editing ................................................................................................ 269
2.6.1.3.1. Creating geometries [2D].......................................................................................... 271
2.6.1.3.2. Multiple boundaries [2D] ........................................................................................... 271
2.6.1.3.3. Geometry formats [2D] ............................................................................................. 271
2.6.1.4. 2D Topology ............................................................................................................. 274
2.6.1.5. Construct Geometry [2D] ......................................................................................... 279
2.6.2.1. Geometry rules for 3D .............................................................................................. 282
2.6.2.2. 3D Geometry Tools .................................................................................................. 284
2.6.2.2.1. Import Geometry [3D] ............................................................................................... 284
2.6.2.2.2. Check Geometry [3D] ............................................................................................... 287
2.6.2.2.4. Scale Geometry [3D] ................................................................................................ 288
2.6.2.2.5. Check Interception [3D] ............................................................................................ 288
2.6.2.2.6. Show /hide normal [3D] ............................................................................................ 288
2.6.2.2.7. Find Axis [3D] ........................................................................................................... 288
2.6.2.2.8. Fix geometry [3D] ..................................................................................................... 288
2.6.2.2.9. Stitch geometry [3D] ................................................................................................. 289
2.6.2.2.10. Extract Border [3D] ......................................................................................... 289
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2.6.2.2.11. Extract Mesh [3D] ........................................................................................... 289

2.6.2.2.12. Geometry Primitives [3D]................................................................................ 289
2.6.2.3. Examine 3D Geometry ............................................................................................. 295
2.6.2.4. Symmetric Surface [3D] ........................................................................................... 296
2.6.2.5. 3D Geometric polygon deletion ................................................................................ 299
2.7. Mesh Data Definition ..................................................................................................................... 302
2.7.1.1. 2D Mesh Tools ......................................................................................................... 302
2.7.1.1.1. Import Mesh [2D] ...................................................................................................... 303
2.7.1.1.3. Generate Mesh [2D] ................................................................................................. 303
2.7.1.1.4. Check Mesh [2D] ...................................................................................................... 303
2.7.1.1.5. Area and Volume [2D] .............................................................................................. 303
2.7.1.1.6. Manual Remesh [2D] ................................................................................................ 304
2.7.1.2.1. System Setup ........................................................................................................... 307
2.7.1.2.2. User-Defined MESH [2D] ......................................................................................... 318
2.7.1.3.1. Maximum interference depth (RMDPTH) [2D, 3D] ................................................... 321
2.7.1.3.2. Maximum stroke increment (RMSTRK) [2D, 3D] ..................................................... 321
2.7.1.3.3. Maximum time increment (RMTIME) [2D, 3D] ......................................................... 321
2.7.1.3.4. Maximum step increment (RMSTEP) [2D, 3D]......................................................... 321
2.7.2.1. 3D Mesh Tools ......................................................................................................... 323
2.7.2.1.1. Import Mesh [3D] ...................................................................................................... 323
2.7.2.1.3. Finer internal mesh [3D] ........................................................................................... 324
2.7.2.1.4. Manual Remesh [3D] ................................................................................................ 324
2.7.2.2.1. System Setup ........................................................................................................... 328
2.7.2.2.2. User-Defined Mesh Settings [3D] ............................................................................. 337
2.7.2.3.1. General Remesh criteria [3D] ................................................................................... 340
2.7.2.3.2. Remeshing Method [3D] ........................................................................................... 341
2.8. Movement Controls Definition ....................................................................................................... 344
2.8.1. Translational Movement .................................................................................................. 346
2.8.1.1. Speed control ........................................................................................................... 346
2.8.1.2. Force control ............................................................................................................ 349
2.8.1.3. Hammer Energy ....................................................................................................... 351
2.8.1.3.1. Anvil Type Hammer [2D, 3D] .................................................................................... 353
2.8.1.3.2. Counterblow Hammer [2D, 3D] ................................................................................ 355
2.8.1.4. Screw press ............................................................................................................. 357
2.8.1.5. Tools Option ............................................................................................................. 360
2.8.1.5.1. Hammer/Screw Multiple operation [2D, 3D] ............................................................. 360
xi
2.8.1.5.2. Rolling Multiple operation [2D] ................................................................................. 364

2.8.1.6. Mechanical press ..................................................................................................... 368
2.8.1.6.1. Crank Press [2D, 3D] ................................................................................................ 368
2.8.1.6.2. Knuckle or Wedge Press [2D, 3D] ............................................................................ 372
2.8.1.6.3. Secondary Control (s)............................................................................................... 374
2.8.1.6.4. Elastic Losses ........................................................................................................... 375
2.8.1.7. Hydraulic press ........................................................................................................ 377
2.8.1.7.1. Speed [2D, 3D] ......................................................................................................... 377
2.8.1.7.2. Average strain rate [2D, 3D] ..................................................................................... 378
2.8.1.8. Sliding Die Movement .............................................................................................. 380
2.8.1.9. Path Movement Controls.......................................................................................... 383
2.8.1.9.1. Local and Global Co-ordinates [3D] ......................................................................... 385
2.8.1.9.2. Align Rotation center to object center [2D, 3D] ........................................................ 387
2.8.1.9.3. Synchronize with the defined path data [2D, 3D] ..................................................... 388
2.8.2. Rotational movement ....................................................................................................... 391
2.8.2.1.1. Torque ...................................................................................................................... 393
2.8.3. Torsional movement ........................................................................................................ 395
2.8.3.1.1. Torque ...................................................................................................................... 397
2.8.3.1.3. Energy ...................................................................................................................... 398
2.8.4. Assigning movement to Deformable objects ................................................................... 399
2.8.5. Movement Preview .......................................................................................................... 401
2.8.6. Movement control user subroutines ................................................................................ 403
2.9. Boundary Conditions ..................................................................................................................... 406
2.9.1. Deformation boundary conditions .................................................................................... 410
2.9.1.1. Velocity BCC [2D, 3D] .............................................................................................. 410
2.9.1.2. Free Distortion BCC [ 3D] ........................................................................................ 411
2.9.1.3. Force BCC [2D, 3D] ................................................................................................. 415
2.9.1.4. Pressure BCC [2D, 3D] ............................................................................................ 419
2.9.1.5. Displacement and shrink fit BCC [2D, 3D] ............................................................... 421
2.9.1.6. Movement BCC [2D, 3D].......................................................................................... 421
2.9.1.7. Contact [2D, 3D] ....................................................................................................... 421
2.9.1.8. Symmetry BCC [3D]: ................................................................................................ 422
2.9.1.9. Beginning surface BCC [3D] .................................................................................... 422
2.9.1.10. Free Surface BCC [3D] ............................................................................................... 422
2.9.1.11. Advanced deformation BCC [2D, 3D] ......................................................................... 423
2.9.1.12. Rigid Super Element Window [MO - 3D] ..................................................................... 424
2.9.2. Thermal Boundary Conditions ......................................................................................... 425
2.9.2.1. Heat exchange with the environment BCC [2D/3D] ................................................. 425
2.9.2.2. Temperature BCC [2D, 3D] ...................................................................................... 426
2.9.2.3. Heat flux BCC [2D/3D] ............................................................................................. 426
2.9.2.4. Nodal heat BCC [2D, 3D] ......................................................................................... 426
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2.9.2.5. Advanced Thermal BCC [2D, 3D] ........................................................................... 427

2.9.3. Diffusion Boundary Conditions [DIF] ............................................................................... 427
2.9.3.1. Diffusion with the environment BCC [2D/3D] ........................................................... 427
2.9.3.2. Fixed atom content BCC [2D/3D] ............................................................................. 428
2.9.3.3. Atom flux BCC [2D/3D] ............................................................................................ 428
2.9.3.4. Advanced Diffusion BCC [2D/3D] ............................................................................ 428
2.9.4. Heating Boundary Conditions .......................................................................................... 429
2.9.4.1. Resistance Heating [2D, 3D] .................................................................................... 429
2.9.4.1.1. Voltage BCC ............................................................................................................. 429
2.9.4.1.2. Current Flux BCC ..................................................................................................... 429
2.9.4.2. Induction Heating (BEM) .......................................................................................... 429
2.9.4.2.1. Heating Surface[2D, 3D]........................................................................................... 429
2.9.4.2.2. Coil Begin surface [3D] ............................................................................................. 429
2.9.4.2.3. Coil End surface [3D] ................................................................................................ 429
2.9.4.3. Induction Heating ..................................................................................................... 430
2.10. Object Properties ...................................................................................................................... 432
2.10.1. Deformation properties ........................................................................................................ 434
2.10.1.1. Target Volume (TRGVOL) [2D, 3D] ............................................................................ 435
2.10.1.2. Volume penalty constant (PENVOL) [2D, 3D] ............................................................ 436
2.10.1.3. Average strain rate (AVGSTR) [2D, 3D] ..................................................................... 436
2.10.1.4. Limiting strain rate (LMTSTR) [2D, 3D] ....................................................................... 436
2.10.1.5. Generalized plane strain control (ZSTR) [2D] ............................................................. 437
2.10.1.6. Elasto-plastic initial guess (ELPSOL) [2D, 3D] ........................................................... 438
2.10.1.7. Creep solutions (CREEP) [MIC] [2D, 3D] ................................................................... 438
2.10.2. Thermal properties ............................................................................................................... 439
2.10.2.1. Reference temperature (REFTMP) [2D, 3D]............................................................... 439
2.10.2.2. Truncation temperature (TMPLMT) [2D, 3D] .............................................................. 440
2.10.2.3. Stopping temperature (OTPRNG) [2D, 3D] ................................................................ 440
2.10.3. Fracture properties .............................................................................................................. 441
2.10.3.1. Fracture step (FRCSTP) [2D]...................................................................................... 442
2.10.3.2. Fracture elements (FRCNEL) [2D, 3D] ....................................................................... 442
2.10.4. Hardness properties [MIC] ................................................................................................... 443
2.10.5. Induction Heating ................................................................................................................. 444
2.10.5.1. Current frequency [2D, 3D] ......................................................................................... 445
2.10.5.2. Volume Charge [2D, 3D] ............................................................................................. 445
2.10.5.3. Data Definition [2D, 3D] .............................................................................................. 445
2.10.6. Rotational Symmetry ........................................................................................................... 446
2.10.7. Body Force........................................................................................................................... 448
2.10.8. User (USRSUB) ................................................................................................................... 449
2.10.9. Reference [MO] ................................................................................................................... 449
2.10.10. RSE [MO] ..................................................................................................................... 450
2.11. Advanced Object Data Definition ............................................................................................. 453
2.11.1. Object node variables .......................................................................................................... 455
2.11.1.1. Deformation ................................................................................................................. 460
2.11.1.1.1. General ........................................................................................................... 460
xiii
2.11.1.1.2. Stress(Nodal) .................................................................................................. 461

2.11.1.2. Thermal ....................................................................................................................... 464
2.11.1.2.1. Node Temperature (NDTMP) ......................................................................... 464
2.11.1.2.2. Heat (NDHEAT) .............................................................................................. 464
2.11.1.2.3. Heat flux (NDFLUX)........................................................................................ 465
2.11.1.2.4. Boundary condition code (BCCTMP) ............................................................. 465
2.11.1.2.5. Boundary condition function (BCCTFN) ......................................................... 465
2.11.1.3. Diffusion [DIF] ............................................................................................................. 466
2.11.1.3.1. Atom Percentage (DATOM) ........................................................................... 466
2.11.1.3.2. Diffusion Flux (CRBFLX) ................................................................................ 466
2.11.1.3.3. Diffusion BCC (BCCCRB) .............................................................................. 467
2.11.1.4.1. Electric field intensity (VOTAGE) ................................................................... 468
2.11.1.4.2. Resistance BCC (BCCRHT) ........................................................................... 469
2.11.1.4.3. Current Flux (RHTFLX) .................................................................................. 469
2.11.1.5. User ............................................................................................................................. 469
2.11.2. Object element variables ..................................................................................................... 471
2.11.2.1. Deformation ................................................................................................................. 473
2.11.2.1.1. General ........................................................................................................... 473
2.11.2.1.2. Stress components (STRESS) ....................................................................... 473
2.11.2.1.3. Back Stress Components (YLDS) [MIC] ........................................................ 474
2.11.2.1.4. Strain Rate ...................................................................................................... 474
2.11.2.1.5. Mat. Angle (MATAXI)...................................................................................... 474
2.11.2.2. Hardness [MIC] ........................................................................................................... 475
2.11.2.2.1. Hardness (HDNOBJ1) .................................................................................... 475
2.11.2.2.2. Cooling Time (HDNOBJ2) .............................................................................. 476
2.11.2.4. User ............................................................................................................................. 478
2.11.2.5. Microstructure ............................................................................................................. 479
2.11.2.5.1. Grain ............................................................................................................... 479
2.11.2.5.2. Phase (Transformation) .................................................................................. 479
2.11.2.5.3. Size ................................................................................................................. 481
2.11.2.5.4. Texture ........................................................................................................... 481
2.11.3. Boolean Operation ............................................................................................................... 482
2.11.4. Data Interpolation ................................................................................................................ 487
2.11.5. Slicing .................................................................................................................................. 489
2.11.6. Object edge variables .......................................................................................................... 490
2.11.6.1. Deformation ................................................................................................................. 491
2.11.6.1.1. Deform BCC (ECCDEF) ................................................................................. 491
2.11.6.1.2. Function BCC (ECDEFN) ............................................................................... 491
2.11.6.1.3. Pressure (ECPRES) ....................................................................................... 491
2.11.6.2. Thermal ....................................................................................................................... 491
2.11.6.2.1. Node Temperature (ECCTMP) ....................................................................... 492
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Table of Contents
2.11.6.2.2. Flux (ECHFLX) ............................................................................................... 492

2.11.6.3. Diffusion ...................................................................................................................... 492
2.11.6.3.1. Diffusion (ECCATM) ....................................................................................... 492
2.11.6.3.2. Function BCC (ECATFN) ............................................................................... 492
2.11.6.3.3. Diffusion Flux (ECAFLX) ................................................................................ 492
2.11.6.4.1. Heating BCC (ECCRHT) ................................................................................ 493
2.11.6.4.2. Function BCC (ECRHFN) ............................................................................... 493
2.11.6.4.3. Current Flux (ECRFLX) .................................................................................. 493
2.11.7. Mirror Merge: ....................................................................................................................... 494
2.12. Object Positioning..................................................................................................................... 497
2.12.1. Drag ..................................................................................................................................... 497
2.12.2. Offset Positioning ................................................................................................................. 499
2.12.2.1. Centroid Positioning .................................................................................................... 500
2.12.3. Interference positioning ....................................................................................................... 501
2.12.4. Rotational positioning .......................................................................................................... 503
2.12.5. Drop positioning ................................................................................................................... 506
2.12.6. Flip ....................................................................................................................................... 508
2.12.7. Coupled positioning ............................................................................................................. 510
2.13. Inter-object Data Definition ....................................................................................................... 513
2.13.1. Contact relation (CNTACT).................................................................................................. 516
2.13.2. Deformation inter-object definition ....................................................................................... 518
2.13.2.1. Friction (FRCFAC) [2D, 3D] ........................................................................................ 518
2.13.2.1.1. Constant Shear (sticking) [2D, 3D] ................................................................. 518
2.13.2.1.2. Coulomb (sliding) [2D, 3D] ............................................................................. 519
2.13.2.1.3. Hybrid [2D, 3D] ............................................................................................... 519
2.13.2.1.4. Tau (shear stress) [2D] ................................................................................... 520
2.13.2.2. Separation criteria (SEPRES) [2D, 3D] ....................................................................... 526
2.13.2.2.1. Non Separable (SEPRES) [3D] ...................................................................... 526
2.13.2.2.2. Separation Density (SEPDEN) [2D] ............................................................... 527
2.13.2.3. Self Contact [2D, 3D] .................................................................................................. 528
2.13.2.4. Contact Method [3D] ................................................................................................... 528
2.13.2.4.1. Penalty ............................................................................................................ 528
2.13.2.4.2. Conforming Coupling ...................................................................................... 529
2.13.3. Thermal inter-object definition ............................................................................................. 530
2.13.3.1. Interface heat transfer coefficient (IHTCOF) [2D, 3D] ................................................ 530
2.13.3.2. Relative rotation (FRCROT) [2D] ................................................................................ 530
2.13.4. Heating Inter-object definition .............................................................................................. 532
2.13.4.1. Resistance [2D, 3D] .................................................................................................... 532
2.13.5. Friction window (FRCWIN) definition ................................................................................... 533
2.13.6. Tool Wear Window .............................................................................................................. 535
2.13.6.1. Archard's model [2D, 3D] ............................................................................................ 535
2.13.6.2. Usui's model ................................................................................................................ 536
2.13.7. Rigid Contact ....................................................................................................................... 538
2.14. Database Generation ............................................................................................................... 540
xv
2.14.1. Data errors ........................................................................................................................... 541

2.14.2. Data warnings ...................................................................................................................... 541
2.14.3. The Benefits of Integrated DB ............................................................................................. 541
2.15. 2D to 3D Conversion ................................................................................................................ 544
2.15.1. Built-in Conversion module Introduction .............................................................................. 545
2.15.1.1. Procedure to convert objects from 2D to 3D ............................................................... 546
2.15.2. Advanced Geometry Options............................................................................................... 550
2.15.2.1. Extrude ........................................................................................................................ 550
2.15.2.2. Revolve ....................................................................................................................... 550
3 Running Simulations .............................................................................................................................. 553
3.1. Start, Stop and resume Simulation................................................................................................ 554
3.2. Interactive and batch modes using Run option ............................................................................. 559
3.2.1. Interactive Mode .............................................................................................................. 559
3.2.2. Batch Queue Mode .......................................................................................................... 559
3.2.3. Queuing Simulations ........................................................................................................ 559
3.2.3.1. Running Batch Queue Server and Simulation Server ............................................. 559
3.2.3.2. Computer configuration requirements...................................................................... 559
3.2.3.3. Batch Queue Server setup ...................................................................................... 560
3.2.3.4. Simulation Server setup .......................................................................................... 561
3.2.3.5. Run (Options) settings ............................................................................................. 562
3.2.3.5.1. Other Run options dialog features ............................................................................ 563
3.2.3.5.2. Job options ............................................................................................................... 564
3.2.3.5.3. Multiprocessor options .............................................................................................. 564
3.3. Simulation Graphics ...................................................................................................................... 567
3.4. Process Monitor............................................................................................................................. 570
3.4.1. Running jobs .................................................................................................................... 570
3.4.2. Queuing jobs .................................................................................................................... 571
3.5. Registering MPICH ....................................................................................................................... 574
3.5.1. Registering 64 bit 3D FEM engine in PC ........................................................................ 574
3.5.2. Running 64 bit 3D FEM engine in Linux/PC .................................................................... 574
3.6. Running simulations remotely ....................................................................................................... 577
3.7. E-mail the results ........................................................................................................................... 586
3.8. Trouble Shooting Simulation Running ........................................................................................... 589
3.8.1. Message file messages ................................................................................................... 589
3.8.2. Simulation aborted by user error or License related errors. ............................................ 589
3.8.3. Cannot remesh at a negative step ................................................................................... 590
3.8.4. Remeshing is highly recommended ................................................................................ 590
3.8.5. Negative Jacobian ........................................................................................................... 591
3.8.6. Solution does not converge ............................................................................................. 591
3.8.7. Stiffness matrix is non-positive definite ........................................................................... 594
3.8.8. Zero pivot ......................................................................................................................... 594
3.8.9. Extrapolation of data ........................................................................................................ 594
3.8.10. Bad Element Shape ............................................................................................................. 595
3.8.11. Inconsistent Step Number .................................................................................................. 595
4 Integrated Post Processor...................................................................................................................... 599
xvi
Table of Contents
4.1. Post Processor Overview .............................................................................................................. 600

4.1.1. Post Processor layout ...................................................................................................... 601
4.1.1.1. Display Window........................................................................................................ 602
4.1.1.2. Graphic Utilities ........................................................................................................ 602
4.1.1.3. Object Tree .............................................................................................................. 602
4.1.1.4. Display Modification Window ................................................................................... 603
4.2. Graphical Display .......................................................................................................................... 605
4.2.1. Object Tree Options ......................................................................................................... 605
4.2.1.1. Object Display Modes [2D, 3D] ................................................................................ 605
4.2.1.2. Tree Levels and Functions [2D, 3D] ........................................................................ 606
4.2.1.2.1. Problem Data [2D, 3D] ............................................................................................. 606
4.2.1.2.2. Object Data [2D, 3D] ................................................................................................ 608
4.2.1.2.3. Additional Post Processing Functions [2D, 3D] ........................................................ 612
4.2.1.3. Object Control Bar [2D, 3D] ..................................................................................... 612
4.2.2. Display window options ................................................................................................... 614
4.2.2.1. RMB Options ............................................................................................................ 614
4.2.2.2. Multi-Viewports Options ........................................................................................... 615
4.2.2.3. Window Options ....................................................................................................... 615
4.3. Graphical Utilities ........................................................................................................................... 617
4.3.1. File Menu ......................................................................................................................... 617
4.3.2. Viewport Menu ................................................................................................................. 619
4.3.2.1. Multiple viewport control........................................................................................... 620
4.3.2.2. Link View Port .......................................................................................................... 620
4.3.2.3. Copy Viewport .......................................................................................................... 620
4.3.2.4. Refresh (F5) ............................................................................................................. 621
4.3.2.5. View Fit (F4) ............................................................................................................. 621
4.3.2.6. View back (F3) ......................................................................................................... 621
4.3.2.7. Load and Save ......................................................................................................... 621
4.3.3. Display Menu ................................................................................................................... 622
4.3.4. Model Menu ..................................................................................................................... 622
4.3.5. Step Tools ........................................................................................................................ 622
4.3.5.1. Steps list ................................................................................................................... 622
4.3.5.1.1. Style .......................................................................................................................... 623
4.3.5.1.2. Range ....................................................................................................................... 624
4.3.5.1.3. Type .......................................................................................................................... 624
4.3.5.1.4. Data Purging ............................................................................................................. 624
4.3.5.2. Step Manipulation Buttons ....................................................................................... 624
4.3.6. Tools Menu ...................................................................................................................... 626
4.3.7. Window Menu .................................................................................................................. 627
4.3.8. View Menu ....................................................................................................................... 627
4.3.9. Options Menu .................................................................................................................. 628
4.3.10. Help Menu............................................................................................................................ 628
4.3.11. Animation Tools ................................................................................................................... 628
4.3.11.1. 3D View Mode ............................................................................................................. 628
4.3.11.2. 3D View Settings ......................................................................................................... 628
xvii
4.3.11.3. Animation setup and Control ....................................................................................... 628

4.4. Display Modification...................................................................................................................... 630
4.4.1. Display Property .............................................................................................................. 630
4.4.1.1. Title [2D, 3D] ............................................................................................................ 630
4.4.1.2. Contour [2D, 3D] ...................................................................................................... 631
4.4.1.3. Iso–Surface [3D] ...................................................................................................... 634
4.4.1.4. Vector [2D, 3D] ......................................................................................................... 635
4.4.1.5. Deflection [2D, 3D] ................................................................................................... 637
4.4.1.6. Point tracking [2D, 3D] ............................................................................................. 640
4.4.1.7. Flownet [2D, 3D] ...................................................................................................... 640
4.4.1.8. Axis [2D, 3D] ............................................................................................................ 642
4.4.1.9. Ruler [2D] ................................................................................................................. 642
4.4.1.10. Theme [2D, 3D] ........................................................................................................... 644
4.4.1.11. Selected mark [2D, 3D] ............................................................................................... 645
4.4.2. Graph Property ................................................................................................................ 646
4.4.2.1. Title [2D, 3D] ............................................................................................................ 646
4.4.2.2. X- axis and Y- axis [2D, 3D] ..................................................................................... 647
4.4.2.3. Data [2D, 3D] ........................................................................................................... 649
4.4.2.4. Legend [2D, 3D] ....................................................................................................... 650
4.4.2.5. Tick/Grid [2D, 3D] ..................................................................................................... 651
4.4.2.6. Step tracer [2D, 3D] ................................................................................................. 652
4.4.2.7. Background [2D, 3D] ................................................................................................ 653
4.4.2.8. Theme [2D, 3D] ........................................................................................................ 654
4.4.3. Set Coordinates ............................................................................................................... 655
4.4.3.1. Rectangular and Cylindrical co-ordinates ................................................................ 655
4.4.3.2. User Defined [2D, 3D] .............................................................................................. 656
4.4.3.3. Local (material axis) [2D, 3D] ................................................................................... 659
4.4.4. Set Viewport Property ...................................................................................................... 661
4.4.5. Set Lighting Property ....................................................................................................... 662
4.4.6. Color Bar Property ........................................................................................................... 665
4.4.6.1. General [2D, 3D] ...................................................................................................... 665
4.4.6.2. User-Defined [2D, 3D] .............................................................................................. 666
4.4.7. Set User Defined Variable Tracking ................................................................................ 667
4.4.8. Set Unit Conversion factors ............................................................................................. 669
4.5. Post-Processing features .............................................................................................................. 671
4.5.1. Simulation Summary........................................................................................................ 671
4.5.1.1. Operation ................................................................................................................. 673
4.5.1.2. Step .......................................................................................................................... 674
4.5.2. State Variables ................................................................................................................ 674
4.5.2.1. Different State variable types ................................................................................... 677
4.5.2.2. Normal Pressure [3D] ............................................................................................... 678
4.5.2.3. Plot type ................................................................................................................... 678
4.5.2.4. Deflection [2D, 3D] ................................................................................................... 679
4.5.2.5. Histogram [2D, 3D] ................................................................................................... 679
4.5.2.6. Scaling [2D, 3D] ....................................................................................................... 682
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Table of Contents
4.5.2.7. Object Limits ............................................................................................................ 683

4.5.2.8. User Variables .......................................................................................................... 683
4.5.2.9. Usage ....................................................................................................................... 683
4.5.2.10. Interpreting state variables [2D, 3D] ........................................................................... 683
4.5.2.10.1. Damage .......................................................................................................... 683
4.5.2.10.2. Displacement .................................................................................................. 684
4.5.2.10.3. Density ............................................................................................................ 684
4.5.2.10.4. Strain .............................................................................................................. 684
4.5.2.10.5. Strain Rate ...................................................................................................... 686
4.5.2.10.6. Stress ............................................................................................................. 686
4.5.2.10.7. Velocity ........................................................................................................... 687
4.5.2.10.8. Back Stress .................................................................................................... 687
4.5.2.10.9. Normal Pressure............................................................................................. 687
4.5.2.10.10. Force.................................................................................................................. 687
4.5.2.10.11. Temperature ...................................................................................................... 688
4.5.2.10.12. Volume Fraction ................................................................................................ 688
4.5.2.10.13. Grain Size .......................................................................................................... 688
4.5.2.10.14. Hardness ........................................................................................................... 688
4.5.2.10.15. Dominant atom .................................................................................................. 688
4.5.2.10.16. Material .............................................................................................................. 688
4.5.2.10.17. User Variables ................................................................................................... 688
4.5.3. Load Stroke...................................................................................................................... 689
4.5.3.1. Show selected Objects............................................................................................. 689
4.5.3.2. Scale ........................................................................................................................ 689
4.5.3.3. Units ......................................................................................................................... 690
4.5.3.4. Operations ................................................................................................................ 690
4.5.3.5. Continuous stroke .................................................................................................... 690
4.5.3.6. Cumulative energy ................................................................................................... 690
4.5.3.7. Step tracer ................................................................................................................ 690
4.5.3.8. Absolute Value ......................................................................................................... 690
4.5.3.9. Causes of volume loss and their remedies include ................................................. 690
4.5.4. Point Tracking .................................................................................................................. 691
4.5.4.1. Adding Points ........................................................................................................... 692
4.5.4.2. Deleting Points ......................................................................................................... 692
4.5.4.3. Save the points to a file ............................................................................................ 692
4.5.4.4. Load the points to a file ............................................................................................ 692
4.5.4.5. Tracking options ....................................................................................................... 692
4.5.4.6. Save result to file ...................................................................................................... 693
4.5.4.7. Options ..................................................................................................................... 693
4.5.5. FlowNet ............................................................................................................................ 693
4.5.5.1. 2D Flownet ............................................................................................................... 693
4.5.5.1.1. Rectangular Grid [2D] ............................................................................................... 693
4.5.5.1.2. Polygon Pattern [2D] ................................................................................................ 698
4.5.5.1.3. Offset Pattern [2D] .................................................................................................... 701
4.5.5.2. 3D Flownet ............................................................................................................... 704
xix
4.5.5.2.1. Cubic pattern [3D] ..................................................................................................... 705

4.5.5.2.2. Grid Pattern [3D] ....................................................................................................... 707
4.5.5.2.3. Polygon pattern [3D] ................................................................................................. 711
4.5.5.2.4. 2D Offset [3D] ........................................................................................................... 714
4.5.5.2.5. Offset [3D]................................................................................................................. 716
4.5.5.2.6. Surface grid pattern [3D] .......................................................................................... 718
4.5.5.3. User Defined Flownet [2D, 3D] ................................................................................ 721
4.5.5.3.1. Example Case .......................................................................................................... 722
4.5.6. State variable distribution between 2 points .................................................................... 726
4.5.6.1. Straight line [2D, 3D] ................................................................................................ 726
4.5.6.2. Following Boundary.................................................................................................. 728
4.5.6.3. Circular pattern [3D] ................................................................................................. 731
4.5.7. Mirroring ........................................................................................................................... 733
4.5.7.1. Rotational symmetry ................................................................................................ 736
4.5.8. Data Extraction ................................................................................................................ 738
4.5.8.1. Data Type ................................................................................................................. 739
4.5.8.2. Object Data .............................................................................................................. 739
4.5.8.3. Output....................................................................................................................... 739
4.5.8.4. Steps ........................................................................................................................ 740
4.5.8.5. Files .......................................................................................................................... 740
4.5.8.6. Data File ................................................................................................................... 740
4.5.8.7. Extract ...................................................................................................................... 740
4.5.8.8. View.......................................................................................................................... 740
4.5.9. Slicing .............................................................................................................................. 740
4.5.9.1. Mode ........................................................................................................................ 741
4.5.9.2. Slicing plane display................................................................................................. 742
4.5.10. CCT Curve ........................................................................................................................... 742
4.5.11. Object Node Data ................................................................................................................ 742
4.5.12. Object Element Data ............................................................................................................ 744
4.5.13. Object Edge Data ................................................................................................................ 746
4.5.14. Animation controls and saving ............................................................................................. 747
4.5.15. 3D switcher and setup settings ............................................................................................ 749
4.5.15.1. 3D Setup Parameter: [2D, 3D] .................................................................................... 749
4.5.15.2. 3D viewer [2D, 3D] ...................................................................................................... 750
4.5.16. Database Comparison ......................................................................................................... 753
5 DEFORM Integrated Wizards ................................................................................................................ 757
5 1 F23 Template .................................................................................................................................. 757
5.1.1. F23 GUI and Pre Processor ................................................................................................... 758
5.1.1.1. F23 GUI Introduction .............................................................................................. 758
5.1.1.1.1. Display window ......................................................................................................... 760
5.1.1.1.2. Setting modification window ..................................................................................... 760
5.1.1.1.3. Project list window .................................................................................................... 761
5.1.1.1.4. Project record window .............................................................................................. 764
5.1.1.1.5. Graphical utilities window ......................................................................................... 764
5.1.1.2. F23 Pre Processor ................................................................................................. 769
xx
Table of Contents
5.1.1.2.1. Operation Setup ....................................................................................................... 769

5.1.1.2.2. Object definition ........................................................................................................ 776
5.1.1.2.3. 3D Conversion Tool .................................................................................................. 819
5.1.1.2.4. F23 Die Stress Operation ......................................................................................... 823
5.1.1.2.5. Manual BCC definition .............................................................................................. 833
5.1.1.2.6. File structure ............................................................................................................. 834
5.1.2. F23 Simulator.......................................................................................................................... 837
5.1.2.1. Starting the simulation............................................................................................ 839
5.1.3. F23 Post Processor ................................................................................................................ 841
5.1.3.1. Post Processor Overview ....................................................................................... 841
5.1.3.1.1. Project Record Window ............................................................................................ 844
5.1.3.1.2. Post processor tool box ............................................................................................ 847
5.1.3.1.3. F23 Post Processing for Cold Forming .................................................................... 852
5.1.3.1.4. F23 Post Processing for Hot / Warm Forming......................................................... 854
5.1.3.1.5. F23 Post Processing for Die Stress with Heat Transfer ........................................... 856
5.1.3.1.6. F23 Post Processing for Heat transfer ..................................................................... 860
5.2 Inverse Heat Transfer Wizard Manual......................................................................................... 864
5.2.1. Purpose of Inverse heat transfer wizard .......................................................................... 864
5.2.2. Methodology .................................................................................................................... 865
5.2.3. Display window ................................................................................................................ 866
5.2.4. Pre-Processor .................................................................................................................. 867
5.2.5. Running Optimization ...................................................................................................... 878
5.2.6. Results ............................................................................................................................. 879
Shape Rolling Manual ........................................................................................................................... 883
Ring Rolling Manual .............................................................................................................................. 885
Machining Template Manual ................................................................................................................. 887
Extrusion Template Manual ................................................................................................................... 888
6 Multiple Operations Layout .................................................................................................................... 889
6.1. Introduction to MO .......................................................................................................................... 889
6.2. MO Pre layout ................................................................................................................................. 893
6.2.1. Explorer ............................................................................................................................ 894
6.2.2. Operation Editor ............................................................................................................... 897
6.2.2.1. General options ........................................................................................................ 898
6.2.2.2. Operation options ..................................................................................................... 900
6.2.2.3. Object options .......................................................................................................... 901
6.2.3. Operation Tree ................................................................................................................. 905
6.2.3.1. Operation Tree Tool bar options .............................................................................. 906
6.2.3.2. Object Tree Right Mouse button (RMB) options ...................................................... 909
6.2.4. Property Editor ................................................................................................................. 910
6.2.5. Message tab .................................................................................................................... 910
6.2.6. Step Editor ....................................................................................................................... 911
6.2.7. Graphics window ............................................................................................................. 913
6.3. MO Simulation layout ..................................................................................................................... 921
6.3.1. Simulation Options ........................................................................................................... 921
6.3.1.1. Run ........................................................................................................................... 922
xxi
6.3.1.2. Run Options ............................................................................................................. 923

6.3.1.3. Stop .......................................................................................................................... 927
6.3.1.4. Continue ................................................................................................................... 927
6.3.1.5. Refresh ..................................................................................................................... 928
6.3.2. Simulation Jobs tab ......................................................................................................... 928
6.3.3. Simulation Message tab .................................................................................................. 928
6.3.4. Simulation LOG tab ......................................................................................................... 929
6.3.5. Simulation graphics ......................................................................................................... 929
6.3.5.1. Simulation graphics tool bar options: ....................................................................... 929
6.3.5.2. Right Mouse Button options ..................................................................................... 933
6.4. MO Post layout ............................................................................................................................... 938
6.4.1. Step browser .................................................................................................................... 939
6.4.1.1. Step Tools ................................................................................................................ 939
6.4.1.2. Step list magnifier ..................................................................................................... 940
6.4.1.3. Step Selection options ............................................................................................. 940
6.4.1.4. Right Mouse button step browser options................................................................ 940
6.4.2. Graphics window ............................................................................................................. 943
6.4.3. Post Tools ........................................................................................................................ 943
6.4.3.1. State variables ......................................................................................................... 945
Different State variable types ..................................................................................................... 946
6.4.3.1.1. Display options ......................................................................................................... 948
6.4.3.1.2. State variables settings [2D,3D] ............................................................................... 949
6.4.3.1.3. Controls settings ....................................................................................................... 950
6.4.3.1.4. Deflection settings [2D, 3D] ...................................................................................... 951
6.4.3.1.5. Reference settings .................................................................................................... 951
6.4.3.1.6. Tool wear settings .................................................................................................... 954
6.4.3.2. Tools......................................................................................................................... 956
6.4.3.2.1. Summary [2D,3D]: .................................................................................................... 956
6.4.3.2.2. Load-Stroke [2D,3D]: ................................................................................................ 956
6.4.3.2.3. Point tracking [2D,3D]:.............................................................................................. 956
6.4.3.2.4. Flownet [2D,3D]: ....................................................................................................... 956
6.4.3.2.5. Animation setup [2D,3D]:.......................................................................................... 956
6.4.3.2.6. 3D viewer [3D]: ......................................................................................................... 957
6.4.3.2.7. Mirroring [3D]: ........................................................................................................... 957
6.4.3.2.8. Slicing [3D]: .............................................................................................................. 957
6.4.4. Output tree ....................................................................................................................... 957
6.5. Menu options .................................................................................................................................. 960
6.5.1. Pre Mode menu bar options ............................................................................................ 960
6.5.1.1. File Menu.................................................................................................................. 960
6.5.1.1.1. New Project (Ctrl+N)................................................................................................ 961
6.5.1.1.2. Open Project (Ctrl+O) ............................................................................................... 962
6.5.1.1.3. Save (Ctrl+S) .......................................................................................................... 962
6.5.1.1.4. Import (Ctrl+D) .......................................................................................................... 962
6.5.1.1.5. Export ....................................................................................................................... 962
6.5.1.1.6. Folder options ........................................................................................................... 962
xxii
Table of Contents
6.5.1.1.7. Recent Projects ........................................................................................................ 962

6.5.1.1.8. Close (Ctrl+W) .......................................................................................................... 963
6.5.1.1.9. Quit (Ctrl+Q) ............................................................................................................. 963
6.5.1.2. Viewport Menu ......................................................................................................... 963
6.5.1.2.1. Refresh (F5) ........................................................................................................... 963
6.5.1.2.2. View Fit (F3) ............................................................................................................ 964
6.5.1.2.3. Iso view ..................................................................................................................... 964
6.5.1.2.4. Screen upward ......................................................................................................... 964
6.5.1.2.5. View point , , , , , ....................................................................................................... 964
6.5.1.2.6. Load and Save ......................................................................................................... 965
6.5.1.2.7. Lighting ..................................................................................................................... 966
6.5.1.3. Display menu ........................................................................................................... 968
6.5.1.3.1. Shading (F6) ............................................................................................................. 969
6.5.1.3.2. Wireframe (F7) ......................................................................................................... 969
6.5.1.3.3. Shading and Wireframe (F8) .................................................................................... 969
6.5.1.3.4. Feature line or Surface patch ................................................................................... 969
6.5.1.3.5. Add feature line ........................................................................................................ 969
6.5.1.4. Mouse Menu ............................................................................................................ 969
6.5.1.4.1. Measurement ............................................................................................................ 970
6.5.1.4.2. Explorer (select, pan, rotate, zoom) ......................................................................... 970
6.5.1.4.3. Select ........................................................................................................................ 971
6.5.1.4.4. Pan (Shift+LMB) ....................................................................................................... 971
6.5.1.4.5. Rotate (Ctrl+LMB)..................................................................................................... 971
6.5.1.4.6. Dynamic zoom (Alt+LMB) ......................................................................................... 971
6.5.1.4.7. Box Zoom (Ctrl+Alt+LMB) ........................................................................................ 972
6.5.1.5. Tool Menu ................................................................................................................ 972
6.5.1.5.1. Object Nodes ............................................................................................................ 972
6.5.1.5.2. Object Elements ....................................................................................................... 972
6.5.1.5.3. Image setup (Ctrl+M) ................................................................................................ 973
6.5.1.5.4. Capture image (Ctrl+I) .............................................................................................. 973
6.5.1.5.5. Capture Image to clipboard (Ctrl+Shift+I) ................................................................. 973
6.5.1.6. Options Menu ........................................................................................................... 973
6.5.1.6.1. Environment ............................................................................................................. 974
6.5.1.6.2. Preferences .............................................................................................................. 983
6.5.1.7. Project Menu ............................................................................................................ 987
6.5.1.8. Help Menu ................................................................................................................ 988
6.5.1.8.1. Deform manual (F1) ................................................................................................. 989
6.5.1.8.2. What's this? (Shift+F1) .......................................................................................... 989
6.5.1.8.3. About SFTC .............................................................................................................. 989
6.5.1.8.4. About ........................................................................................................................ 989
6.5.2. Simulation Mode menu bar options ................................................................................. 989
6.5.2.1. Simulation Menu ...................................................................................................... 990
6.5.2.1.1. Run (F9) or Submit simulation of the current Project ............................................... 990
6.5.2.1.2. Stop (F10) ................................................................................................................. 990
6.5.2.1.3. Continue (Ctrl+ F9) ................................................................................................... 990
xxiii
6.5.2.1.4. Add to Batch Queue (Ctrl+Shift+A) .......................................................................... 990

6.5.2.1.5. Run options .............................................................................................................. 991
6.5.2.1.6. Process Monitor ........................................................................................................ 991
6.5.3. Post Mode menu bar options ........................................................................................... 991
6.5.4. Tool bar options ............................................................................................................... 991
6.5.4.1. Switch to guided mode ............................................................................................. 992
6.5.4.2. Switch to expert mode.............................................................................................. 992
6.5.4.3. Boolean .................................................................................................................... 992
6.5.4.4. Data Interpolation ..................................................................................................... 992
6.5.4.5. Slicing ....................................................................................................................... 993
6.6. File structure ................................................................................................................................... 995
6.6.1. Normal MO Project Structure........................................................................................... 995
6.6.2. MO DOE Project File structure ........................................................................................ 996
6.6.3. MO Die Stress Project File Structure ............................................................................... 997
6.6.4. Report Generation ........................................................................................................... 998
6.6.5. MO Wizard and Operation specific Files ......................................................................... 998
6.6.6. Operation Specific Important Files .................................................................................. 999
6 7 Operations ..................................................................................................................................... 1001
Operations Setup ............................................................................................................................. 1002
Forming ........................................................................................................................................ 1003
6.7.1.1.Introduction to Forming................................................................................................. 1003
6.7.1.2. Forming 2D Setup ....................................................................................................... 1005
6.7.1.3. Forming 3D Setup ....................................................................................................... 1056
2D Geometry Editing .................................................................................................................... 1133
2D Geometry Editing ................................................................................................................ 1133
Forming Express .......................................................................................................................... 1134
Introduction to Forming Express 2D ......................................................................................... 1134
Die Stress ..................................................................................................................................... 1137
6.7.4.1. Introduction to Die Stress ............................................................................................ 1137
Multiple Blow Hammer-2D ........................................................................................................... 1183
Introduction to Multiple blow Hammer 2D ................................................................................ 1183
Multiple Blow Hammer 2D Setup .............................................................................................. 1184
Heat Treatment ............................................................................................................................ 1185
6.7.6.1 Heat Treatment Manual ................................................................................................ 1185
6.7.6.1.1. Introduction to Heat Treatment ................................................................................ 1185
HT Furnace-3D............................................................................................................................. 1237
Introduction to 3D HT Furnace ................................................................................................. 1237
3D HT Furnace Setup ............................................................................................................... 1238
Heat Transfer Operations 2D and 3D .......................................................................................... 1239
xxiv
Table of Contents
Heating Express 2D and 3D ..................................................................................................... 1239

Heat Transfer Operations Setup ............................................................................................... 1240
Machining Distortion ..................................................................................................................... 1241
6.7.9.1.Introduction to Machining Distortion ............................................................................. 1241
Cogging ........................................................................................................................................ 1277
6.7.1.10.Introduction to Cogging Wizard .................................................................................. 1277
2D to 3D Converter ...................................................................................................................... 1331
2D to 3D Converter ................................................................................................................... 1331
Report Generation ........................................................................................................................ 1332
6.7.13. Report Generation operation ........................................................................................ 1332
6 8 Operations Management ............................................................................................................... 1366
6.8.1. Connecting Operations and passing objects ......................................................................... 1366
6.8.1.1. Connecting Operations ........................................................................................ 1366
6.8.1.2. Passing objects .................................................................................................... 1369
6.8.2. Read from DB concept .......................................................................................................... 1374
6.8.3. Editing Operations ................................................................................................................. 1381
6.8.4. Upgrading Operations ............................................................................................................ 1386
6.8.5. Adding Cycles ........................................................................................................................ 1390
6.8.5.1. Introduction .......................................................................................................... 1390
6.8.5.2. Add Cycles ........................................................................................................... 1390
6.8.5.3. Delete Cycles ....................................................................................................... 1392
6.8.5.4. Changing the number of cycles ........................................................................... 1393
6.8.5.5. Change the name of the cycle operation ............................................................. 1393
6.8.5.6. Moving operations (Drag and Drop) ..................................................................... 1394
6.8.5.7. Examples ............................................................................................................. 1395
6 9 DOE Setup .................................................................................................................................... 1398
6.9.1. Introduction to DOE ............................................................................................................... 1398
6.9.2. DOE and DOE Output Operation Setup ................................................................................ 1401
6.9.2.1. Adding DOE Study ............................................................................................... 1401
6.9.2.2. Defining DOE Variables ....................................................................................... 1402
6.9.2.3. Failed DOE variable definition ............................................................................. 1416
6.9.2.4. Deleting DOE variable.......................................................................................... 1416
6.9.2.5. DOE Table ........................................................................................................... 1417
6.9.2.6. DOE Sampling ..................................................................................................... 1419
6.9.2.6.1. Latin Hypercube Sampling ..................................................................................... 1419
6.9.2.6.2. Full Factorial Sampling ........................................................................................... 1420
6.9.2.6.3. User defined Sampling ........................................................................................... 1421
6.9.2.7. Defining DOE output operation ............................................................................ 1421
6.9.2.7.1. Select operation and object .................................................................................... 1421
6.9.2.7.2. Define Region of Interest ........................................................................................ 1422
6.9.2.7.3. Define outputs ........................................................................................................ 1426
6.9.2.7.4. Define Variable Constraints .................................................................................... 1432
6.9.2.7.5. Define Fill Constraints ............................................................................................ 1433
xxv
6.9.3. DOE Simulation Running and Monitoring .............................................................................. 1436

6.9.4. DOE Post Processor .............................................................................................................. 1441
6.9.4.1. Introduction .......................................................................................................... 1441
6.9.4.2. DOE Post Components ........................................................................................ 1441
6.9.4.3. Graphics view ....................................................................................................... 1442
6.9.4.4. Table View ........................................................................................................... 1444
6.9.4.5. Response Surface Plots ( and ) ........................................................................... 1445
6.9.4.6. Sensitivity Plot ...................................................................................................... 1447
6.9.4.7. Tornado Chart ...................................................................................................... 1449
6.9.4.8. Scatter Plot ........................................................................................................... 1451
6.9.4.9. Histogram Plot ...................................................................................................... 1452
6 11 Die Stress Study .......................................................................................................................... 1455
6.11.1. Introduction to Die Stress Study .......................................................................................... 1455
6.11.2. Die Stress Study for 2D Setup ............................................................................................. 1457
6.11.2.2. Step selection ........................................................................................................... 1458
6.11.2.3. Objects window ........................................................................................................ 1459
6.11.2.4. Object Types ............................................................................................................ 1460
6.11.2.5. Dies .......................................................................................................................... 1461
6.11.2.5.1. General ......................................................................................................... 1461
6.11.2.5.2. Geometry ...................................................................................................... 1461
6.11.2.5.3. Object Mesh ................................................................................................. 1462
6.11.2.5.5. Object Material ............................................................................................. 1465
6.11.2.5.7. Initialize ......................................................................................................... 1468
6.11.2.5.8. Fixtures ......................................................................................................... 1469
6.11.2.6. Controls .................................................................................................................... 1469
6.11.2.9. Generate DB ............................................................................................................ 1473
6.11.2.9.1. Check data ................................................................................................... 1473
6.11.2.9.3. Append key file ............................................................................................. 1474
6.11.3. Die Stress Study for 3D setup ............................................................................................. 1476
6.11.3.2. Step selection ........................................................................................................... 1477
6.11.3.3. Objects window ........................................................................................................ 1478
6.11.3.4. Object Types ............................................................................................................ 1479
6.11.3.5. Dies .......................................................................................................................... 1480
6.11.3.5.1. General ......................................................................................................... 1480
6.11.3.5.2. Geometry ...................................................................................................... 1480
xxvi
Table of Contents
6.11.3.5.3. Object Mesh ................................................................................................. 1481

6.11.3.5.5. Object Material ............................................................................................. 1484
6.11.3.5.7. Initialize ......................................................................................................... 1487
6.11.3.5.8. Fixtures ......................................................................................................... 1488
6.11.3.6. Controls .................................................................................................................... 1488
6.11.3.9. Generate DB ............................................................................................................ 1492
6.11.3.9.1. Check data ................................................................................................... 1492
6.11.3.9.3. Append key file ............................................................................................. 1493
7 Next Gen Post Processor..................................................................................................................... 1495
7.1. Introduction to Next Gen Post Processor ..................................................................................... 1495
7.2. Next Gen Post Processor Layout ................................................................................................. 1498
7.2.1. Step View Window ......................................................................................................... 1499
7.2.1.1. Step tools and operation selection options ............................................................ 1499
7.2.1.2. Steps Selection options.......................................................................................... 1500
7.2.1.3. Step list.................................................................................................................. 1500
7.2.2. Graphics window ........................................................................................................... 1501
7.2.3. Post features settings modifications window ................................................................. 1501
7.2.4. Object Tree .................................................................................................................... 1501
7.2.5. Report Generation ......................................................................................................... 1501
7.2.6. Post Features ................................................................................................................ 1502
7.2.6.1. State Variables ....................................................................................................... 1502
7.2.6.2. Region of Interest ................................................................................................... 1503
7.2.6.3. Summary Graphs .................................................................................................. 1507
7.2.6.4. Load/Stroke Graphs .............................................................................................. 1510
7.2.6.5. Point Tracking ........................................................................................................ 1512
7.2.6.6. Coupon Data Extraction ......................................................................................... 1517
7.2.6.7. Flownet Tracking .................................................................................................... 1520
7.2.6.8. Set User defined variable tracking ......................................................................... 1521
7.2.6.9. Mirror Symmetry ..................................................................................................... 1523
7.2.6.10. Slicing ........................................................................................................................ 1530
7.2.6.11. Data Extraction .......................................................................................................... 1534
7.2.6.12. Measurement options ................................................................................................ 1536
7.2.6.13. Animation Setup ........................................................................................................ 1537
7.2.6.14. 3D viewer and setup [2D] .......................................................................................... 1540
7.2.6.15. 3D Setup Parameter [2D] .......................................................................................... 1541
7.2.6.16. Text and Image Annotations .................................................................................... 1542
7.2.6.17. Object Nodes ............................................................................................................ 1546
xxvii
7.2.6.18. Object Elements ........................................................................................................ 1547

7.3. Report Generation ........................................................................................................................ 1551
7.3.1. Introduction: ................................................................................................................... 1551
7.3.2. Report ............................................................................................................................ 1551
7.3.3. Chapter .......................................................................................................................... 1553
7.3.3.1. Chapter title ............................................................................................................ 1555
7.3.3.2. Operation range selection ...................................................................................... 1555
7.3.3.3. Sections.................................................................................................................. 1555
7.3.3.3.1. Summary ................................................................................................................ 1555
7.3.3.3.2. Graph (load-Stroke) ................................................................................................ 1557
7.3.3.3.3. State Variable ......................................................................................................... 1559
7.3.3.3.4. Region of Interest ................................................................................................... 1565
7.3.3.3.5. Coupon ................................................................................................................... 1568
7.3.3.3.6. Point Tracking ......................................................................................................... 1570
7.3.3.3.7. Flownet ................................................................................................................... 1573
7.3.3.3.8. Metal Flow .............................................................................................................. 1576
7.3.3.3.9. Post user variables tracking ................................................................................... 1578
7.3.3.3.10. User defined ................................................................................................. 1583
7.4. Editing Chapters ........................................................................................................................... 1594
7.5. Working with DB in PIP mode ...................................................................................................... 1597
8 User Routines ...................................................................................................................................... 1603
8.1. 2D User Routines...................................................................................................................... 1604
8.2. 2D User Defined FEM Routines .............................................................................................. 1607
8.2.1. Summary of subroutines and calling structure of user-defined FEM routines ........... 1610
8.2.2. Passing data to user routines from the Preprocessor ................................................ 1613
8.2.3. User defined flow stress routines (USRMTR) ............................................................ 1615
8.2.4. User defined movement control (USRDSP) ............................................................... 1619
8.2.5. User defined node and element value (USRUPD) .................................................... 1624
8.2.6. User defined damage models (USRDMG) ................................................................. 1629
8.2.7. User defined material models (USRMAT).................................................................. 1632
8.2.8. User defined nodal boundary conditions (USRBCC) ................................................. 1636
8.2.9. User defined lubricant heat transfer (USRBCC2) ...................................................... 1640
8.2.10. User defined general routine (USRMSH) ....................................................................... 1644
8.2.11. Compiling user routines for UNIX platforms................................................................... 1648
8.2.12. Running the modified FEM engine for UNIX platforms .................................................. 1648
8.2.13. Running the modified FEM engine for Windows platforms ............................................ 1649
8.3. 2D User-Defined Post-Processing Routines ........................................................................... 1651
8.3.2. Compiling user routines on Linux/Unix ...................................................................... 1654
8.3.3. Compiling user routines on Windows ......................................................................... 1655
8.3.4. Running the modified post-processor ........................................................................ 1655
8.4 3D User Routines....................................................................................................................... 1657
8.4.1. 3D User defined FEM routines ................................................................................... 1663
xxviii
Table of Contents
8.4.1.1. User defined data (USRDEF) ............................................................................. 1663

8.4.1.2. User defined flow stress routines (USRMTR) .................................................... 1665
8.4.1.3. User defined movement control (USRDSP) ....................................................... 1669
8.4.1.4. User defined node and element value (USRUPD) ............................................. 1675
8.4.1.5. User defined damage models (USRDMG) ....................................................... 1679
8.4.1.6. User defined general routine (USRMSH) ........................................................... 1681
8.4.2. Running the modified FEM engine for UNIX platforms .............................................. 1685
8.4.3. 3D User defined post-processing routines ................................................................. 1687
8.4.5. Compiling post-processing user routines on UNIX machines .................................... 1690
8.4.6. Running the modified post-processor in UNIX ........................................................... 1690
8.4.7. Compiling post-processing user routines on Windows machines.............................. 1691
9 Appendices .......................................................................................................................................... 1693
Appendix I: Elementary Concepts in Metalforming and Finite Element Analysis............................... 1693
AI.1. Definition of stress, strain and strain rate ............................................................................... 1693
AI.2. Introduction to FEM theory ..................................................................................................... 1700
AI.3. Modeling Material Behavior in FEM ..................................................................................... 1703
Appendix II: Installation of DEFORM v11.0 in windows ...................................................................... 1706
AII.1. INTRODUCTION .......................................................................................................... 1706
AII.2. INSTALLATION REQUIREMENTS .............................................................................. 1706
AII.3. INSTALLING THE SECURITY KEY DEVICE .............................................................. 1706
AII.4. INSTALLING DEFORM v11.0 IN WINDOWS .............................................................. 1707
AII.5. TROUBLE SHOOTING ................................................................................................ 1756
AII.6. QUESTIONS / PROBLEMS ......................................................................................... 1761
Appendix III: Installation of DEFORM V10.2.1 in UNIX or LINUX ....................................................... 1763
AIII.1. INTRODUCTION ........................................................................................................... 1763
AIII.2. INSTALLATION REQUIREMENTS ............................................................................... 1763
AIII.3. OBTAINING AND INSTALLING THE SUPPORTING SOFTWARE ............................. 1764
AIII.3.1. Obtaining and Installing LZMA ............................................................................... 1764
AIII.3.2. Obtaining and Installing GNU tar on Linux ............................................................. 1765
AIII.3.3. Obtaining and Installing GNU tar on HP-UX........................................................... 1765
AIII.4. OBTAINING AND INSTALLING THE DEFORM SOFTWARE ..................................... 1765
AIII.4.1. Installation Procedure ............................................................................................. 1765
AIII.4.1.1. Install the Sentinel Key Driver for Linux systems ................................................... 1765
AIII.4.1.2. Installing DEFORM and/or License Manager on Linux .......................................... 1766
AIII.4.1.3. Instructions for running 64bit DEFORM on Linux operating systems .................... 1769
AIII.4.1.4. Installing DEFORM and/or License Manager on HP-UX ....................................... 1769
AIII.4.1.5. Setup a user account ............................................................................................. 1770
AIII.5. HP Intel Xeon XC-2000 Cluster updates ....................................................................... 1771
AIII.5.1. How to install Open Fabrics Infiniband support ...................................................... 1771
AIII.6. System Execution .......................................................................................................... 1772
AIII.7. QUESTIONS / PROBLEMS .......................................................................................... 1773
Appendix IV: License Manager .......................................................................................................... 1775
Appendix V: Launching the Simulation Engine from a Command Prompt (Windows only) ................ 1777
Appendix VI: Running DEFORM in text mode ................................................................................... 1780
xxix
AVI.1. Assembling input data..................................................................................................... 1780

AVI.2. Brief Introduction to Keywords ........................................................................................ 1781
AVI.3. Help For Optimization Users ........................................................................................... 1782
AVI.4. Running a Simulation ...................................................................................................... 1782
AVI.5. Extracting the Results ..................................................................................................... 1782
Appendix VII: Determining 'R' coefficients for anisotropy models ....................................................... 1785
Appendix VIII: The Elasto-Plastic Model ............................................................................................. 1788
AVIII.1. Material Properties ............................................................................................................. 1788
AVIII.2. Object data ......................................................................................................................... 1789
AVIII.3. Solution procedure ............................................................................................................. 1790
AVIII.4. Strain Definition .................................................................................................................. 1790
AVIII.5. Advice on Predicting Springback ....................................................................................... 1790
AVIII.6. Note on Convergence issues with Elasto-Plastic material models .................................... 1790
AVIII.7. DEFORM convention rule for material interpolation .......................................................... 1791
AVIII.8. Comments on “Flow curve definition for Rate-dependent material” .................................. 1791
Appendix IX: Part is deforming, but strain does not accumulate......................................................... 1796
Appendix X: Checking the forming loads results of a simulation ....................................................... 1800
Appendix XI: Preventing leakage of nodes in sectioned simulations .................................................. 1803
Appendix XII: Generating a Circular Geometry With a Hole .............................................................. 1807
Appendix XIII: 2D Topology Definition and Multiple Material Groups ................................................ 1812
AXIII.1. 2D Topology Definition ....................................................................................................... 1813
AXIII.2. User Interface for Topology Building ................................................................................. 1814
AXIII.3. Summary ............................................................................................................................ 1819
AXIII.4. Applications of Multiple Material Groups ........................................................................... 1820
AXIII.5. Two examples from the references.................................................................................... 1820
Appendix XIV : Near-surface mesh functions...................................................................................... 1822
Appendix XV: Modeling of a Spring-Loaded Sliding Die Using Force Controlled Objects .................. 1829
Appendix XVI: Finer Points on Using Force Controlled Dies ............................................................. 1835
AXVI.1. Objective ............................................................................................................................ 1835
AXVI.2. Theory................................................................................................................................ 1835
AXVI.3. Solution .............................................................................................................................. 1835
Appendix XVII: Details of Movement control in Spinning motion.KEY ................................................ 1837
AXVII.1. Introduction ............................................................................................................... 1837
AXVII.2. Movement controls for spinning ............................................................................... 1837
Appendix XVIII: Rotating Workpiece Simulations ............................................................................... 1840
AXVIII.1. Moving tools about a non-spinning workpiece ........................................................... 1841
AXVIII.2. Spinning Workpiece.................................................................................................... 1843
Appendix XIX: The Double Concave Corner Constraint ..................................................................... 1848
Appendix XX: Die Stress Analysis - Theory ....................................................................................... 1852
AXX.1. Overview ............................................................................................................................. 1852
AXX.2. Types of analyses ............................................................................................................... 1853
AXX.3. Practical Considerations ..................................................................................................... 1855
AXX.4. Die Failure Modes .............................................................................................................. 1856
AXX.5. Required Data..................................................................................................................... 1857
AXX.6. Die Stress Setup ................................................................................................................. 1857
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AXX.7. Defining a Press Fit ............................................................................................................ 1858

AXX.8. Quick Summary of Shrink Fit Boundary Condition ............................................................. 1858
AXX.9. Important Measurements of Stress .................................................................................... 1860
AXX.10. Interpretation of Stress ............................................................................................... 1861
Appendix XXI: Die Stress Analysis in DEFORM Theory and Practical Applications ......................... 1865
AXXI.1. Die Stress Analysis Importance .............................................................................. 1865
AXXI.2. Modes of Die Failure ............................................................................................... 1865
AXXI.3. Die Stress State ....................................................................................................... 1865
AXXI.4. Die Stress Analysis Effective Stress ....................................................................... 1866
AXXI.5. Die Stress Analysis Fatigue Failure ........................................................................ 1867
AXXI.6. Die Stress Example Low Complexity ...................................................................... 1867
AXXI.7. Die Stress Example Medium Complexity ................................................................ 1868
AXXI.8. Die Stress Example - High Complexity ................................................................... 1869
AXXI.9. Coupled Die Stress Analysis ................................................................................... 1870
Appendix XXII: How to do coupled die stress analysis for 3D models ................................................ 1873
Appendix XXIII: Setting up fracture with element deletion in DEFORM-2D ........................................ 1877
Appendix XXIV: Fracture with Element Deletion and Damage Softening ........................................... 1882
Appendix XXV: Setting up induction heating in DEFORM-2D ............................................................ 1888
AXXV.1. Defining the simulation ............................................................................................... 1888
AXXV.2. Post-Processing the simulation .................................................................................. 1892
Appendix XXVI: A Theoretical Background to Resistance Heating Concepts Implemented in DEFORM-
2D ........................................................................................................................................................ 1894
Appendix XXVII: Running an inertia weld simulation in DEFORM ..................................................... 1898
Appendix XXVIII: Running creep simulations in DEFORM-2D .......................................................... 1900
Appendix XXIX: Adding Gas Trap Calculation to a Simulation ........................................................... 1905
Appendix XXX: Sheet Forming in DEFORM-3D ................................................................................. 1908
AXXX.1. Theory - Anisotropy ..................................................................................................... 1908
AXXX.2. Theory – Assumed Strain Formulation ....................................................................... 1910
AXXX.3. Simulation Principles ................................................................................................... 1911
AXXX.4. Example: Square cup drawing process ...................................................................... 1911
AXXX.5. Example: Cylindrical cup drawing process ................................................................. 1913
Appendix XXXI: Shape Rolling Simulation Overview .......................................................................... 1918
AXXXI.1. System features ........................................................................................................... 1918
AXXXI.2. Characteristics ............................................................................................................. 1918
Appendix XXXII: Setting up Steady State Extrusion ........................................................................... 1921
AXXXII.1. General description ........................................................................................................ 1921
AXXXII.2. Data preparation ............................................................................................................ 1921
AXXXII.3. Some techniques for running the steady state extrusion ............................................... 1922
AXXXII.4. EXTDIE.DAT preparation ............................................................................................... 1925
AXXXII.5. EDGEINFO.DAT ............................................................................................................ 1926
AXXXII.6. PKVEL.DAT.................................................................................................................... 1926
Appendix XXXIII: Setting up 3D machining models ............................................................................ 1929
Appendix XXXIV: Data Files ................................................................................................................ 1933
Appendix XXXV: How to Create DEFORM Animations for Distribution ............................................. 1947
AXXXV.1. Recommended Method ................................................................................................. 1947
xxxi
AXXXV.2. Legacy Method .............................................................................................................. 1948

10 License Manager ................................................................................................................................ 1951
10.1. DEFORM License Setup ............................................................................................................ 1951
10.1.1. Computer configuration requirements ............................................................................... 1951
10.1.2. Computer Locations in DEFORM Setup ............................................................................ 1951
10.1.3. How to setup the new license configuration ...................................................................... 1952
10.2. License Monitoring ..................................................................................................................... 1968
10.3. Monitoring Services ................................................................................................................ 1971
10.4. Trouble Shooting License Issues ............................................................................................... 1973
10.4.1. Identifying License Server 3.0.4 Problem .......................................................................... 1973
10.4.2. Solving License Server v3.0.4 Problem: Specific Topic Issues......................................... 1974
10.4.2.1. Password problem .................................................................................................... 1974
10.4.2.2. Hardware key problem check list .............................................................................. 1974
10.4.2.3. Old license is running ................................................................................................ 1974
10.4.2.4. Register service problem .......................................................................................... 1974
10.4.2.5. Service startup problem ............................................................................................ 1975
10.4.3. Miscellaneous Service Related Notes ............................................................................... 1975
10.4.3.1. Instructions to unregister the service ........................................................................ 1975
11 Keyword Documentation .................................................................................................................... 1979
A ....................................................................................................................................................... 1979
B ....................................................................................................................................................... 1994
C....................................................................................................................................................... 2018
D....................................................................................................................................................... 2059
E ....................................................................................................................................................... 2117
F ....................................................................................................................................................... 2177
G ...................................................................................................................................................... 2230
H....................................................................................................................................................... 2269
I ........................................................................................................................................................ 2286
J ....................................................................................................................................................... 2307
K ....................................................................................................................................................... 2310
L ....................................................................................................................................................... 2314
M ...................................................................................................................................................... 2331
N....................................................................................................................................................... 2384
O ...................................................................................................................................................... 2399
P ....................................................................................................................................................... 2417
R....................................................................................................................................................... 2448
S ....................................................................................................................................................... 2470
T ....................................................................................................................................................... 2517
U....................................................................................................................................................... 2580
V ....................................................................................................................................................... 2602
W ...................................................................................................................................................... 2619
Y ....................................................................................................................................................... 2635
Z ....................................................................................................................................................... 2641
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Table of Contents
A ....................................................................................................................................................... 2648
B ....................................................................................................................................................... 2652
C....................................................................................................................................................... 2660
D....................................................................................................................................................... 2671
E ....................................................................................................................................................... 2696
F ....................................................................................................................................................... 2724
G ...................................................................................................................................................... 2737
H....................................................................................................................................................... 2741
I ........................................................................................................................................................ 2743
M ...................................................................................................................................................... 2746
N....................................................................................................................................................... 2769
O ...................................................................................................................................................... 2771
P ....................................................................................................................................................... 2784
R....................................................................................................................................................... 2794
S ....................................................................................................................................................... 2803
T ....................................................................................................................................................... 2821
U....................................................................................................................................................... 2825
V ....................................................................................................................................................... 2828
W ...................................................................................................................................................... 2830
Y ....................................................................................................................................................... 2846
Labs ......................................................................................................................................................... 2853
Quick reference ................................................................................................................................... 2853
Quick Reference .............................................................................................................................. 2853
Cold Forming ................................................................................................................................... 2854
Hot Forming ..................................................................................................................................... 2859
Basic labs ......................................................................................................................................... 2870
Lab 1. Geometry Manipulation - XYR Format ........................................................................... 2870
1.4. Display Manipulation .................................................................................................... 2877
1.5. Point Selection .............................................................................................................. 2877
Lab 2. Geometry Input - IGES Files ...................................................................................... 2879
Lab 3. Geometry Input - Geometry Correction ...................................................................... 2884
xxxiii

Lab 4. Uniform Mesh Generation .......................................................................................... 2888
4.2. Generating a Uniform Mesh ......................................................................................... 2888
Lab 5. Spike Forging - Mesh Generation for Billet ................................................................ 2893
5.2. Setting Meshing Parameters and Generating the Mesh .............................................. 2893
Lab 6. Spike Forging - Mesh Generation for Dies ................................................................. 2898
6.2. Changing Simulation Controls ...................................................................................... 2898
6.3. Generating Mesh on the Dies ....................................................................................... 2898
6.4. Saving the Problem under a Different Name................................................................ 2899
Lab 7. Spike Forging - Die Positioning .................................................................................. 2902
7.2. Changing Object Positioning ........................................................................................ 2902
Lab 8. Spike Forging - Pre-Processing ................................................................................. 2907
8.4. Importing Material Data ................................................................................................ 2908
8.6. Assigning a Velocity to the Primary Die ....................................................................... 2909
8.7. Assigning Inter-Object Relationships ........................................................................... 2910
8.10. Exiting DEFORM-2D3D ........................................................................................ 2914
Lab9. Spike Forging Simulation & Post-Processing ......................................................... 2917
9.2. Starting the Simulation ................................................................................................ 2917
Lab 10. Heat Transfer - Heating Billet in Furnace ....................................................................... 2926
10.3. Creating Billet Geometry ...................................................................................... 2927
10.4. Meshing the Billet ................................................................................................. 2928
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Table of Contents
10.5. Defining Billet Heat Transfer Boundary Conditions .............................................. 2928

10.6. Importing Billet Material ........................................................................................ 2928
10.7. Saving the Problem and Running the Simulation ................................................. 2930
10.8. Post-Processing ................................................................................................... 2930
Lab 11. Restarting Heat Transfer ............................................................................................... 2933
11.2. Revisiting Simulation Controls .............................................................................. 2934
11.3. Revisiting Boundary Conditions ........................................................................... 2934
11.4. Writing the Database and Continuing the Simulation ........................................... 2935
11.5. Post-Processing ................................................................................................... 2935
Lab 12. Spike Forging - Non-Isothermal ..................................................................................... 2940
12.2. Setting Simulation Controls ................................................................................. 2940
12.3. Importing Materials ............................................................................................... 2941
12.4. Setting Object Data .............................................................................................. 2941
12.5. Object Positioning ................................................................................................. 2942
12.6. Inter-Object Relationships ................................................................................... 2942
12.7. Writing the Database and Running the Simulation .............................................. 2942
12.8. Post-Processing ................................................................................................... 2942
Lab 13. CHANGING DIES - SPIKE FORGING ........................................................................... 2946
13.2. Loading Step from the Previous Database........................................................... 2946
13.3. Creating New Die Geometry (Flat Top Die) ......................................................... 2946
13.4. Positioning New Top Die ...................................................................................... 2947
13.5. Defining Self Contact for the Billet ........................................................................ 2947
13.6. Modifying Billet Mesh Settings ............................................................................. 2947
13.7. Defining New Contact Boundary Conditions ........................................................ 2947
13.8. Initializing Stroke for Primary Die ........................................................................ 2947
13.9. Redefining Simulation Input ................................................................................. 2948
13.10. Writing the Database ................................................................................................ 2948
13.12. Post-processing the Results ..................................................................................... 2948
Lab 14. HAMMER FORGING SIMULATION – SPIKE FORGING (ISOTHERMAL) ................... 2952
14.1. Creating a new problem ....................................................................................... 2952
14.2. Importing Spike Forging (Isothermal) .................................................................. 2952
14.3. Importing Material ................................................................................................ 2952
14.4. Defining Movement Control for Hammer Forging ................................................ 2952
14.8. Continuing the Simulation..................................................................................... 2954
Lab 15. SCREW PRESS SIMULATION - Spike Forging (Isothermal) ........................................ 2956
xxxv

15.4. Defining Movement Control for Screw Press ....................................................... 2956
Lab 16. DIE STRESS ANALYSIS - Multiple Dies (NON -ISOTHERMAL) .................................. 2960
16.2. Importing Spike Forging (Non-Isothermal) ........................................................... 2961
16.4. Defining BCC’s ..................................................................................................... 2961
16.5. Checking Material Data - Elastic Properties ......................................................... 2962
Lab 17. DIE STRESS ANALYSIS - MULTIPLE DIES (NON-ISOTHERMAL)............................. 2965
17.3. Defining BCC’s ..................................................................................................... 2966
17.4. Defining Poisson’s Ratio and Young’s Modulus ................................................... 2966
Lab18. DIE STRESS ANALYSIS - SHRINK FIT (NON-ISOTHERMAL)................................... 2969
18.3. Defining BCC’s ..................................................................................................... 2970
18.4. Selecting a Material .............................................................................................. 2970
Lab 19. 2D SIMULATION OF SLAB ROLLING .......................................................................... 2973
19.3. Creating Object #1 ................................................................................................ 2973
19.4. Creating Object #2 ................................................................................................ 2974
19.5. Setting Inter-Object Properties ............................................................................. 2974
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Table of Contents

Lab 20. MECHANICAL PRESS SIMULATION - SPIKE FORGING (ISOTHERMAL) ................ 2977
20.3. Changing Movement Control ................................................................................ 2978
Lab 21. HYDRAULIC PRESS SIMULATION - SPIKE FORGING (ISOTHERMAL) ................... 2980
21.3. Defining Movement Control for Hydraulic Press .................................................. 2981
Lab 22. FORMING OF A ROLLER BEARING RACE USING A POROUS MATERIAL ............. 2984
22.2. Importing and Checking Geometry....................................................................... 2984
22.3. Defining Properties of Object #1 .......................................................................... 2984
22.4. Assigning Movement to Object #2 ........................................................................ 2985
22.5. Assigning Inter-Object Properties ........................................................................ 2985
22.6. Checking Object Positioning ................................................................................ 2986
22.11. Post-Processing the Results .................................................................................... 2986
Lab 23. 2D HAMMER MULTIPLE OPERATIONS ...................................................................... 2989
23.1. Create a regular hammer problem ....................................................................... 2990
Lab 24. 2D ROLLING MULTIPLE OPERATIONS ...................................................................... 2994
24.1. Create a regular rolling problem ........................................................................... 2994
24.4. Continuing Simulation........................................................................................... 2997
Lab 25. 2D STUB SHAFT LAB .................................................................................................. 3000
25.1. Create Geometry .................................................................................................. 3001
xxxvii
25.2. Mesh Generation. ................................................................................................. 3008

25.4. Running a simulation ............................................................................................ 3018
25.5. Postprocessing the operation ............................................................................... 3019
25.6. Running a second operation ................................................................................ 3021
25.7. Postprocessing ..................................................................................................... 3024
25.8. Tool Stress Analysis ............................................................................................. 3026
25.9. Simulating thermal effects .................................................................................... 3029
25.10. Warm Stub shaft with Mechanical Press movement ................................................ 3033
25.11. Warm Stub shaft with Hydraulic Press movement ................................................... 3034
25.12. Warm Stub shaft with Screw press movement......................................................... 3035
25.13. Warm Stub shaft with Hammer movement.............................................................. 3035
F2 Wizard Labs ................................................................................................................................ 3037
Lab 1. F2 Cold Forming Labs ....................................................................................................... 3037
1.1. Create a New Problem. Import and Manipulate Workpiece ......................................... 3037
1.2. Import tools – Manipulate Object Display ..................................................................... 3039
1.3. Bad Geometry and Geometry Repair ........................................................................... 3040
1.4. Generate Mesh ............................................................................................................. 3042
1.5. Completing Pre Processing .......................................................................................... 3043
1.6. Run Simulation and Postprocess ................................................................................. 3045
1.9. Die Stress .................................................................................................................... 3049
Cutting Wizard Labs......................................................................................................................... 3053
Machining Cutting Lab1 ............................................................................................................... 3053
Heat Treatment Labs ....................................................................................................................... 3055
1. Modeling of a Heating Operation with Phase Transformation. ............................................... 3055
1.3. Loading the Material Properties ................................................................................... 3057
1.4. Creating Object #1 ........................................................................................................ 3057
1.5. Creating Object #2 ........................................................................................................ 3060
1.6. Defining Inter-Object Relations..................................................................................... 3060
2. Modeling of Carburization of a Gear Tooth ............................................................................. 3064
2.3. Setting Boundary Conditions ........................................................................................ 3065
3. Modeling of Diffusion of a Gear Tooth .................................................................................... 3068
xxxviii
Table of Contents

4. Modeling of Quenching of a Gear Tooth ................................................................................. 3072
4.3. Setting Object Properties .............................................................................................. 3073
5. PREPARING MATERIAL AND PHASE TRANSFORMATION DATA .................................... 3077
5.1. The Basic Concepts ..................................................................................................... 3077
5.3. Setting Units ................................................................................................................. 3080
5.5. Setting Inter-Material Properties ................................................................................... 3081
5.6. Saving Materials ........................................................................................................... 3085
6. Grain Modeling ........................................................................................................................ 3087
6.1. Introduction ................................................................................................................... 3087
6.2. Load Deformation Keyword File ................................................................................... 3088
6.3. Specify Grain-related Material Data ............................................................................. 3088
6.4. Input Initial Grain Variables .......................................................................................... 3089
6.5. Run Deformation Simulation......................................................................................... 3090
6.6. Prepare and Run Air-cooling Simulation ...................................................................... 3090
6.7. Prepare and Run Water-Quenching Simulation ........................................................... 3090
6.8. Post Processing ............................................................................................................ 3091
6.9. Changing Conditions .................................................................................................... 3093
Inverse Heat Wizard Labs ............................................................................................................... 3097
Inv Heat Wizard Lab2 ................................................................................................................... 3099
Tool Wear Labs ................................................................................................................................ 3101
Tool Wear Lab .............................................................................................................................. 3101
Resistance Heating Labs ................................................................................................................. 3103
Resistance Heating Lab ............................................................................................................... 3103
13 2D Labs MO ................................................................................................................................... 3105
2D MO Labs Index ........................................................................................................................... 3105
MO Basic Labs ................................................................................................................................. 3108
Lab 01 Geometry Manipulation and Uniform mesh ..................................................................... 3108
1.2. Adding Forming operation ............................................................................................ 3111
1.3. Selecting Geometry Type ............................................................................................. 3112
1.4. Adding Objects ............................................................................................................. 3113
1.5. Workpiece ..................................................................................................................... 3114
1.6. Creating Workpiece geometry ...................................................................................... 3115
xxxix
1.7. Workpiece mesh page .................................................................................................. 3119

Lab02. Geometry Correction ........................................................................................................ 3123
2.1. Geometry Type ............................................................................................................. 3127
2.2. Adding Object ............................................................................................................... 3127
2.3. Geometry Editing .......................................................................................................... 3128
Lab 03 Spike Isothermal .............................................................................................................. 3134
3.2. Adding Forming operation - Spike ................................................................................ 3137
3.3. Spike Isothermal- Block ................................................................................................ 3173
3.4. Close MO Wizard ......................................................................................................... 3186
Lab 04 Heat Transfer ................................................................................................................... 3188
4.2. Adding Heating Express operation ............................................................................... 3191
4.3. Changing operation Name............................................................................................ 3192
4.4. Heating in Furnace ....................................................................................................... 3193
4.5. Heating Furnace Process setup ................................................................................... 3193
4.6. Workpiece Setup .......................................................................................................... 3194
4.7. Furnace Heat Condition Setup ..................................................................................... 3198
4.8. Heating Furnace Simulation controls ........................................................................... 3199
4.9. DB Generation for Heating Furnace ............................................................................. 3200
4.10. Air cool operation .................................................................................................. 3201
4.11. Air cooling Heat Condition Setup ......................................................................... 3201
4.12. Simulation Controls For Air cooling ...................................................................... 3201
4.13. DB Generation For Air Cooling ............................................................................. 3202
Lab 05 Spike Non-Isothermal ....................................................................................................... 3209
5.3. Geometry type selection ............................................................................................... 3214
5.4. Loading Materials of Workpiece and Dies .................................................................... 3215
5.5. Adding Objects ............................................................................................................. 3218
5.6. Workpiece Setup .......................................................................................................... 3219
5.7. Top Die Setup ............................................................................................................... 3228
5.8. Bottom Die Setup ......................................................................................................... 3233
5.9. Controls ........................................................................................................................ 3237
5.10. Contact ................................................................................................................. 3238
Lab 06 Die Stress ......................................................................................................................... 3253
6.1. Introduction ................................................................................................................... 3253
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Table of Contents
6.3. Add Die stress study ..................................................................................................... 3254

6.4. Step selection ............................................................................................................... 3255
6.5. Top Die Setup ............................................................................................................... 3256
6.6. Bottom Die Setup ......................................................................................................... 3258
6.7. Simulation controls Setup ............................................................................................. 3260
6.9. Starting the simulation .................................................................................................. 3260
6.10. Post processing the results .................................................................................. 3261
Lab 07 Mechanical Press ............................................................................................................. 3265
7.3. Import Database ........................................................................................................... 3267
7.4. Assigning Top Die Movement....................................................................................... 3268
Lab 08 Hammer Press ................................................................................................................. 3274
8.3. Importing Database ...................................................................................................... 3275
8.4. Material List .................................................................................................................. 3276
8.5. Assigning Temperature for Billet .................................................................................. 3277
8.6. Assigning Hammer Movement for Top Die .................................................................. 3278
8.7. Generating 1st Operation Database ............................................................................. 3279
8.8. Simulating 1st Operation .............................................................................................. 3280
8.9. Post-Processing the 1st operation Results .................................................................. 3280
8.10. Adding 2nd operation ........................................................................................... 3282
8.11. Adding objects ...................................................................................................... 3282
8.12. Workpiece Setup in 2nd operation ....................................................................... 3282
8.13. Top Die Setup in 2nd operation ............................................................................ 3283
8.14. Bottom Die Setup in 2nd operation ...................................................................... 3283
8.15. Generate Inter-object Contacts ............................................................................ 3284
8.17. Generating 2nd operation Database .................................................................... 3286
8.18. Simulating 2nd operation ...................................................................................... 3286
8.19. Post-Processing the 2nd Operation Results ........................................................ 3287
8.20. Closing MO Wizard ............................................................................................... 3288
Lab 09 Hammer Multiple Operation ............................................................................................. 3290
9.3. Importing Keyfile ........................................................................................................... 3292
9.4. Editing Blow table ......................................................................................................... 3292
9.5. Generating Inter-object Contact ................................................................................... 3293
9.6. Generating Database ................................................................................................... 3294
xli
Lab 10 Hydraulic press................................................................................................................. 3297

10.4. Assigning Hydraulic movement for Top Die ......................................................... 3300
Lab 11 Screw press...................................................................................................................... 3305
11.4. Material List .......................................................................................................... 3307
11.5. Assigning Temperature for Billet .......................................................................... 3307
11.6. Assigning Screw press movement for Top Die .................................................... 3308
Lab 12 Die Stress with Holder ...................................................................................................... 3313
12.3. Step selection ....................................................................................................... 3314
12.4. Add Object ............................................................................................................ 3315
12.5. Top Die Setup ....................................................................................................... 3316
12.6. Bottom Die Setup ................................................................................................. 3318
12.7. Holder ................................................................................................................... 3320
12.9. Simulation controls ............................................................................................... 3325
Lab 13 Die Stress with Shrink Fit ................................................................................................. 3331
13.3. Step selection ....................................................................................................... 3333
13.4. Add Objects .......................................................................................................... 3334
13.5. Top Die Setup ....................................................................................................... 3335
13.6. Bottom Die Setup ................................................................................................. 3337
13.7. Holder Setup ......................................................................................................... 3339
13.8. Ring Setup ............................................................................................................ 3343
13.10. Simulation controls ................................................................................................... 3348
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Table of Contents
2D_DOE_lab .................................................................................................................................... 3354

1. 2D DOE Lab1 ........................................................................................................................... 3354
1.1. Nominal Project setup and simulation .......................................................................... 3354
1.2. Check and define the Nominal Project ......................................................................... 3357
1.3. Add DOE Project .......................................................................................................... 3363
1.4. Add die geometry variation as DOE variable ............................................................... 3365
1.5. Add Friction coefficient as DOE variable ...................................................................... 3375
1.6. Check DOE table .......................................................................................................... 3379
1.7. DOE Samples definition ............................................................................................... 3380
1.8. Define DOE Output operation....................................................................................... 3380
1.9. Simulate DOE project ................................................................................................... 3387
1.10. Review the DOE results ....................................................................................... 3391
2D_Machining_Distortion_lab .......................................................................................................... 3400
1.3. Object window: ............................................................................................................. 3403
1.4. Workpiece: .................................................................................................................... 3404
1.7. Controls window: .......................................................................................................... 3411
1.9. Contact: ........................................................................................................................ 3412
1.12. DB generation: ...................................................................................................... 3415
• F3 Wizard Labs ................................................................................................................... 3418
• Shape Rolling Wizard labs .................................................................................................. 3418
• Ring Rolling Wizard labs ..................................................................................................... 3418
• Extrusion Wizards Labs ...................................................................................................... 3419
• 3D Cutting Labs................................................................................................................... 3419
• Tool Wear Labs ................................................................................................................... 3419
Extrusion Wizards Labs ................................................................................................................... 3421
Basic Labs ....................................................................................................................................... 3428
Lab 1. Block Pre-Processing ................................................................................................. 3428
xliii

1.4. Display Manipulation and point selection ..................................................................... 3435
1.5. Other DISPLAY Window Icons ..................................................................................... 3435
Lab 2. Block Die Positioning ................................................................................................ 3438
2.1. Introduction ................................................................................................................... 3438
2.3. Importing Dies............................................................................................................... 3439
2.8. Object Positioning ......................................................................................................... 3445
2.10. Generating a Database ........................................................................................ 3453
2.11. Saving the Problem .............................................................................................. 3454
Lab 3. BLOCK FORGING SIMULATION & POST-PROCESSING ...................................... 3456
3.1. Introduction ................................................................................................................... 3456
Lab 4. Square Ring ............................................................................................................... 3467
4.1. Introduction ................................................................................................................... 3468
4.5. Setting Symmetry Boundary Conditions ....................................................................... 3469
4.7. Finishing Setup and Running Simulation ..................................................................... 3473
4.8. Post Processing ............................................................................................................ 3473
Lab 5. SPIKE FORGING -TRANSFER FROM FURNACE TO DIES ................................... 3477
5.1. Introduction ................................................................................................................... 3477
5.4. Inserting New Objects .................................................................................................. 3478
5.6. Defining Billet Heat Transfer Boundary Conditions ...................................................... 3481
5.7. Importing Billet Material ................................................................................................ 3482
5.9. Post-Processing ........................................................................................................... 3483
xliv
Table of Contents
Lab 6. SPIKE FORGING - DWELL ON BOTTOM DIE ......................................................... 3489

6.1. Introduction ................................................................................................................... 3489
6.3. Die Meshing and Thermal Boundary Conditions .......................................................... 3491
6.4. Importing Die Material .................................................................................................. 3493
6.5. Billet Positioning ........................................................................................................... 3494
6.9. Post-Processing ........................................................................................................... 3497
Lab 7. SPIKE FORGING - FORGING BLOW 1 .................................................................... 3501
7.1. Introduction ................................................................................................................... 3501
7.7. Revisiting Inter-Object Relations .................................................................................. 3504
7.9. Post-Processing ........................................................................................................... 3505
Lab 8. SPIKE FORGING - DIE CHANGE AND BLOW 2 ...................................................... 3509
8.1. Introduction ................................................................................................................... 3509
8.3. Changing Top Die for Blow 2........................................................................................ 3510
8.4. Defining New Top Die Boundary Conditions ................................................................ 3510
8.6. Redefining Inter-Object Contact ................................................................................... 3511
8.9. Post-Processing ........................................................................................................... 3512
Lab 9. Die Stress Analysis .................................................................................................... 3515
9.1. Introduction ................................................................................................................... 3515
9.3. Loading a Database Step ............................................................................................. 3516
9.5. Adding Additional Tools and Deleting the Billet............................................................ 3516
9.8. Post-Processing ........................................................................................................... 3522
Lab 10. STEERING LINK ............................................................................................................ 3527
10.1. Introduction ........................................................................................................... 3527
10.5. Assigning Object Temperature ............................................................................. 3530
xlv
10.6. Activating Volume Compensation ........................................................................ 3530

10.7. Assigning Movement Controls .............................................................................. 3531
10.8. Assigning Boundary Conditions ........................................................................... 3531
10.9. Assigning Stopping Controls ................................................................................ 3531
10.10. Assigning Step Controls ........................................................................................... 3532
10.11. Importing Material Data ............................................................................................ 3532
10.12. Assigning Inter-Object Boundary Conditions ............................................................ 3532
10.13. Writing the Database and Running the Simulation .................................................. 3532
10.14. Viewing and Comparing Results .............................................................................. 3533
10.15. Running a Hammer Simulation................................................................................. 3534
Lab 11. Gear Carrier ................................................................................................................... 3537
11.1. Introduction ........................................................................................................... 3537
11.2. Planning the Simulation ........................................................................................ 3538
11.6. Defining Billet Boundary Conditions ..................................................................... 3540
11.7. Defining Billet Temperature .................................................................................. 3540
11.8. Loading Material Data .......................................................................................... 3540
11.9. Setting Top Die Movement ................................................................................... 3540
11.10. Assigning Simulation Controls .................................................................................. 3541
11.11. Running the Furnace Transfer Operation ................................................................. 3541
11.12. Running the Dwell Operation.................................................................................... 3541
11.13. Running the Upset Operation ................................................................................... 3542
11.14. Running the Transfer Operation ............................................................................... 3543
11.15. Running the Second Forming Operation .................................................................. 3543
Lab 12. Hot Forming Lab - Tee Billet .......................................................................................... 3546
12.1. Create a New Problem. Import and Manipulate Geometry ................................. 3546
12.2. Import Tools – Manipulate Object Display............................................................ 3547
12.3. Bad Geometry & Geometry Repair ...................................................................... 3547
12.4. Mesh Generation .................................................................................................. 3549
12.5. Completing Pre Processing .................................................................................. 3550
12.6. Run Simulation and Postprocessor ...................................................................... 3552
12.7. Restarting Simulation ........................................................................................... 3553
12.8. Simulating Temperature Effects ........................................................................... 3555
12.9. Symmetry.............................................................................................................. 3557
12.10. Die stress .................................................................................................................. 3559
Lab 13. Stub shaft Lab ................................................................................................................ 3561
13.1. Create a New Problem. Import Geometry ............................................................ 3561
13.2. Bad Geometry and Geometry Repair ................................................................... 3562
13.3. Mesh Generation. Tool Geometry Input. .............................................................. 3562
13.5. Running a Simulation ........................................................................................... 3575
13.6. Postprocessing ..................................................................................................... 3575
13.7. Running a Second Operation ............................................................................... 3578
xlvi
Table of Contents
13.8. Postprocessing ..................................................................................................... 3581

13.9. Symmetry / Thermal Operations .......................................................................... 3587
13.10. Tool Stress Analysis ................................................................................................. 3600
13.11. Mechanical Press ..................................................................................................... 3602
Machining Labs ................................................................................................................................ 3607
Turning lab1 ................................................................................................................................. 3607
Drilling lab1 ................................................................................................................................... 3609
Machining Wizard turning Lab1 .................................................................................................... 3611
Ring Rolling Wizard labs .................................................................................................................. 3613
Ring Rolling Lab1 ......................................................................................................................... 3613
Ring Rolling Lab2 ......................................................................................................................... 3615
Ring Rolling Lab3 ......................................................................................................................... 3617
Ring Rolling Lab4 ......................................................................................................................... 3619
Shape Rolling Wizard labs ............................................................................................................... 3621
ALE Lab1 ...................................................................................................................................... 3621
Lagrangian Lab ............................................................................................................................ 3623
Tool Wear Lab ................................................................................................................................. 3625
Tool Wear Lab1 ............................................................................................................................ 3625
Inverse Heat lab ............................................................................................................................... 3627
15 3D Labs MO ................................................................................................................................... 3629
3D MO Labs Index ........................................................................................................................... 3629
• Die Stress Labs ................................................................................................................... 3629
• Tool Wear Labs ................................................................................................................... 3629
Basic labs in MO .............................................................................................................................. 3631
Lab 1. Block .................................................................................................................................. 3631
1.2. Setting material properties ............................................................................................ 3636
1.4. Controls ........................................................................................................................ 3644
1.6. Setting Simulation controls ........................................................................................... 3653
1.10. Step Tools and Step Selection ............................................................................. 3656
1.11. State Variables ..................................................................................................... 3656
1.12. Point Tracking ....................................................................................................... 3657
1.13. Slicing Objects ...................................................................................................... 3659
1.14. Exiting MO Wizard ................................................................................................ 3661
Lab 2. Square Ring ...................................................................................................................... 3663
2.1. Introduction ................................................................................................................... 3663
2.3. Adding Objects ............................................................................................................. 3669
xlvii
2.4. Creating Workpiece Object........................................................................................... 3670

2.5. Loading Workpiece Geometry ...................................................................................... 3671
2.7. Assigning Material to the Billet ..................................................................................... 3673
2.8. Setting symmetry boundary conditions ........................................................................ 3674
2.9. Creating Top die Object................................................................................................ 3676
2.10. Loading Top die Geometry ................................................................................... 3677
2.11. Assigning Movement to Top die ........................................................................... 3677
2.12. Inter-Object relationships...................................................................................... 3678
2.13. Finish the setup and running the simulation ......................................................... 3680
2.14. Running Simulation .............................................................................................. 3683
2.15. Post Processing .................................................................................................... 3684
Lab 3. Spike Forging ............................................................................................................. 3689
3.1. Spike Forging - Transfer from Furnace to Dies ............................................................ 3689
3.2. Spike Forging - Dwell On Bottom Die ........................................................................... 3704
3.3. Spike Forging - Forging Blow1 ..................................................................................... 3721
3.4. Spike Forging - Die Change and Blow2 ....................................................................... 3736
Lab 4. Steering Link .............................................................................................................. 3743
4.1. Introduction ................................................................................................................... 3743
4.2. Creating New Problem ................................................................................................. 3743
4.3. Adding operation and Objects ...................................................................................... 3744
4.4. Defining Workpiece ..................................................................................................... 3744
4.5. Defining Top Die ........................................................................................................... 3751
4.6. Defining Bottom Die ...................................................................................................... 3753
4.7. Positioning Objects ....................................................................................................... 3754
4.8. Assigning Inter-Object Boundary Conditions ................................................................ 3755
4.9. Assigning Stopping Controls ........................................................................................ 3757
4.11. Data Base Generation .......................................................................................... 3760
4.12. Post processing .................................................................................................... 3760
Forming Express Labs ..................................................................................................................... 3764
Tee Non Isothermal Forging operation ........................................................................................ 3764
Hot Forming Labs ......................................................................................................................... 3787
Creating a New Problem .......................................................................................................... 3787
Lab1- Bolt Forming ....................................................................................................................... 3818
Die Stress Labs ................................................................................................................................ 3855
Die Stress wizard lab1.................................................................................................................. 3855
2. Die Stress wizard Lab2 ........................................................................................................... 3856
2.1. Introduction ................................................................................................................... 3856
2.3. Add Die Stress Study ................................................................................................... 3857
2.4. Adding Objects ............................................................................................................. 3858
2.5. Top Die ......................................................................................................................... 3859
2.6. Bottom Die .................................................................................................................... 3863
xlviii
Table of Contents
2.7. Upper Support .............................................................................................................. 3864

2.8. Lower Support .............................................................................................................. 3869
2.12. Post Processing .................................................................................................... 3873
Report Generation Lab in MO .......................................................................................................... 3877
1. Report Generation Lab in MO .................................................................................................. 3877
1.1. Report generation in Batch post mode ........................................................................ 3877
Machining Distortion Lab ................................................................................................................. 3937
1.3. Object window: ............................................................................................................. 3940
1.4. Workpiece: .................................................................................................................... 3941
1.7. Controls window: .......................................................................................................... 3947
1.9. Contact: ........................................................................................................................ 3948
1.12. DB generation: ...................................................................................................... 3951
Heat Treatment labs ........................................................................................................................ 3954
Lab 1. 3D Heat Treatment Wizard Lab ........................................................................................ 3954
1.1. Introduction ................................................................................................................... 3954
1.2. Starting a New problem ................................................................................................ 3954
1.3. Process Settings ........................................................................................................... 3957
1.4. Material definition ......................................................................................................... 3958
1.5. Workpiece Object Type ................................................................................................ 3959
1.6. Workpiece initialization ................................................................................................. 3965
1.7. Medium Definition ......................................................................................................... 3967
1.8. Scheduled Definition ..................................................................................................... 3970
1.9. Simulation controls ....................................................................................................... 3971
1.12. Post processing .................................................................................................... 3974
16 MO Advanced labs ......................................................................................................................... 3977
Gear Blank ....................................................................................................................................... 3978
MO Advanced Labs : Gear Blank (ENG) ..................................................................................... 3978
xlix

Lab 7. Hammer ..................................................................................................................... 4059
Lab 8. Screw Press............................................................................................................... 4066
MO Advanced Labs : Gear Blank (SI) .......................................................................................... 4102
Lab 7. Hammer ..................................................................................................................... 4182
Lab 8. Screw Press............................................................................................................... 4189

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DEFORM V11.

2.1.3.2.9. Object Edges .............................................................................................................. 70

2.1.5.10. Picking mode [2D, 3D] .................................................................................................. 97

2.2.4.2. Deformation time per step (DTPMAX) [2D].............................................................. 117

2.2.9. Advanced Controls .......................................................................................................... 138

2.3.2.2.6. User Routines ........................................................................................................... 177

2.3.9.1.11. Brozzo damage model.................................................................................... 203

2.5.1. Adding, deleting objects................................................................................................... 249

2.6.2.2.11. Extract Mesh [3D] ........................................................................................... 289

2.8.1.5.2. Rolling Multiple operation [2D] ................................................................................. 364

2.9.2.5. Advanced Thermal BCC [2D, 3D] ........................................................................... 427

2.11.1.1.2. Stress(Nodal) .................................................................................................. 461

2.11.6.2.2. Flux (ECHFLX) ............................................................................................... 492

2.14.1. Data errors ........................................................................................................................... 541

4.1. Post Processor Overview .............................................................................................................. 600

4.3.11.3. Animation setup and Control ....................................................................................... 628

4.5.2.7. Object Limits ............................................................................................................ 683

4.5.5.2.1. Cubic pattern [3D] ..................................................................................................... 705

5.1.1.2.1. Operation Setup ....................................................................................................... 769

6.3.1.2. Run Options ............................................................................................................. 923

6.5.1.1.7. Recent Projects ........................................................................................................ 962

6.5.2.1.4. Add to Batch Queue (Ctrl+Shift+A) .......................................................................... 990

Heating Express 2D and 3D ..................................................................................................... 1239

6.9.3. DOE Simulation Running and Monitoring .............................................................................. 1436

6.11.3.5.3. Object Mesh ................................................................................................. 1481

7.2.6.18. Object Elements ........................................................................................................ 1547

8.4.1.1. User defined data (USRDEF) ............................................................................. 1663

AVI.1. Assembling input data..................................................................................................... 1780

AXX.7. Defining a Press Fit ............................................................................................................ 1858

AXXXV.2. Legacy Method .............................................................................................................. 1948

3.3. Creating a New Object ................................................................................................. 2884

10.5. Defining Billet Heat Transfer Boundary Conditions .............................................. 2928

15.2. Importing Spike Forging (Isothermal) ................................................................... 2956

19.6. Setting Simulation Controls .................................................................................. 2974

25.2. Mesh Generation. ................................................................................................. 3008

3.2. Setting Simulation Controls .......................................................................................... 3068

1.7. Workpiece mesh page .................................................................................................. 3119

6.3. Add Die stress study ..................................................................................................... 3254

Lab 10 Hydraulic press................................................................................................................. 3297

2D_DOE_lab .................................................................................................................................... 3354

1.1. Creating a New Problem .............................................................................................. 3428

Lab 6. SPIKE FORGING - DWELL ON BOTTOM DIE ......................................................... 3489

10.6. Activating Volume Compensation ........................................................................ 3530

13.8. Postprocessing ..................................................................................................... 3581

2.4. Creating Workpiece Object........................................................................................... 3670

2.7. Upper Support .............................................................................................................. 3864

Lab 4. 3D Non-isothermal Air transfer operation .................................................................. 4030

2.1.3.2.9. Object Edges .............................................................................................................. 70

2.1.5.10. Picking mode [2D, 3D] .................................................................................................. 97

2.2.4.2. Deformation time per step (DTPMAX) [2D].............................................................. 117

2.2.9. Advanced Controls .......................................................................................................... 138

2.3.2.2.6. User Routines ........................................................................................................... 177

2.3.9.1.11. Brozzo damage model.................................................................................... 203

2.5.1. Adding, deleting objects................................................................................................... 249

2.6.2.2.11. Extract Mesh [3D] ........................................................................................... 289

2.8.1.5.2. Rolling Multiple operation [2D] ................................................................................. 364

2.9.2.5. Advanced Thermal BCC [2D, 3D] ........................................................................... 427

2.11.1.1.2. Stress(Nodal) .................................................................................................. 461

2.11.6.2.2. Flux (ECHFLX) ............................................................................................... 492

2.14.1. Data errors ........................................................................................................................... 541

4.1. Post Processor Overview .............................................................................................................. 600

4.3.11.3. Animation setup and Control ....................................................................................... 628

4.5.2.7. Object Limits ............................................................................................................ 683