NUMERICAL SIMULATION OF PLASTIC DEFORMATION PROCESS OF

THE GLASS MOLD PARTS

Tudor Chereches1, a, Paul Lixandru1, b, Sergiu Mazuru 2, c, Pavel Cosovschi 3,d,
Daniel Dragnea1, a
1
SC UPS PILOT ARM SRL, Dragomiresti, ROMANIA zip code 137210, ROMANIA
2
UTM, FIMCM, Str. Studentilor, 9, blocul de studii nr. 6, MD-2045, Chisinau, Republica MOLDOVA
3
Glass Factory, Chisinau, Republica MOLDOVA
a
tudor.chereches@yahoo.com, b tudor.chereches@yahoo.com, c s_mazuru@mail.utm.md,
d
c.pashag@gmail.com, e danieldrg2003@yahoo.com

Keywords: numerical simulation; LS-DYNA; physical model; mathematical model; numerical

solution.

Abstract: In our present days numerical
simulation became an important tool of
engineering. Numerical simulation methods
allow quantitative examination of the complex
processes and phenomena in the general area of
physics and also provide an insight in their
dynamic evolution and even can become
important tools for the discovery of new
phenomena. In essence, the numerical simulation
transfer important aspect of physical reality in
discrete forms of mathematical description
recreates and solves the problems on computer
and finally, highlights issues that the analyst
required. This modern numerical method
approach, attacks the original problems in all
their details on a much larger platform with a
much smaller number of assumptions and
approximations, in comparison to traditional
methods. Transposition of the physics problems
in the virtual space, governed by the force of
computers, numerical simulation - as scientific
approach - is becoming increasingly interesting
for many fields of research. Basically, by means
of numerical simulation are addressed fields such
as mechanics deformable solids, fluid mechanics,
aerodynamics, biomechanics, astrophysics.
Numerical simulations follow a similar
procedure to all the scientific approach, which
consists in going through several stages, as
follows: the phenomenon, the physical model,
mathematical model, discrete model, and coding,
numerical solution. In the plastic deformation of
metals are involved, besides the mechanical
properties and some thermal properties because
even if the process is applied in the initial state to
a cold material, along the process changes occur
because of friction between materials and tools
and transformation of plastic mechanical work
into heat. Basic mechanical properties of the
materials are underline through characteristic
diagrams of materials obtained in simple tests of
traction and compression. These tests were
carried out in the Polytechnic University of
Bucharest, Romanian Research & Development
Institute for Gas Turbines COMOTI, Institute for
Calculating and Testing Aero-Astronautic
Structures STRAERO, SC UPS PILOT ARM
Ltd, and Asachi Technical University of Iasi. To
achieve the major objectives of the numerical
simulation of the technological process of cold
plastic deformation, are incorporated into the
physical model three types of surfaces:
cylindrical, conical and profiled. The sizes of the
initial geometry were established in accordance
with the basic dimensions of processed products
by this method. For delimiting surfaces to be
machined, the addition of grip (the tail) has a
reduced diameter. Geometric models provide
strength and rigidity needed for safely and
accurately processing technology of cold plastic
deformation. Geometric models and specimens
which had been subjected to tensile tests,
compression and hardness were made in the
Glass Factory, Chisinau, Moldova.
1. INTRODUCTION
Currently, numerical simulation using computers
has become an important opportunity to address
the problems of engineering and sciences.
Besides the great gains of direct application in
solving engineering problems, numerical
simulations provide an alternative tool for
investigating scientific, substituting costly
experiments, time consuming and sometimes
dangerous, in laboratories or in the field.
Numerical tools are often more useful than
traditional experimental methods, where you
cannot get complete information through
observation, measurement or there are
difficulties data acquisition through other means.
Currently, it using numerical methods based
meshing, as well as numerical mesh free
methods. The most widely used numerical codes
based on finite element method are: ABAQUS,
ANSYS, COSMOSM, LS-DYNA, NASTRAN.
Finite element methods are used in engineering
and scientific problems. In the paper it uses the
finite element method with Lagrange meshing.
2. LABORATORY TESTING
2.1 Primary data processing, framing of the
analyzed material in a standardized category
In the compression test have been tried three lots
of standard specimens with a diameter d = 10
mm, height h = 20 mm, taken from the different
lots of castings. Raw data recorded are altered
due to the compliance of the testing machine and
distortions in the vicinity of the origin (Fig. 1).
Fig. 1. Curves recorded in raw form - Compression test -
Lot no. 1
Distortions of origin were repaired
linearization and translation (Fig. 2).
Fig. 2. Curves recorded repaired in origin - compression
test - Lot no. 1
Diagrams recorded repaired in the origin, for the
three groups of specimens tested at the
compression, it corrects the order to eliminate the
effect of compliance of the testing machine (Fig.
3).
Fig. 3. Proceeding for compensating the compliance of the
testing machine
2.2 Conclusions on compressive characteristic
diagrams
Curves recorded in raw form cannot be used in
applications of the deformable solid mechanics.
Because the procedure of Fig.1 is formulated on
the assumption of linearity of the deformations
parts from the structure of the testing machine,
the result of its application has an approximate
character, but is sufficiently accurate in
applications where plastic deformations are
large. Measurements show that the homogeneity
of the material dispersion varies from lot to lot
and even from one sample to another in the same
lot. The maintaining of the integrity of the
material during processing can be achieved only
if the stress induced in the material is
predominantly compressive (negative triaxiality
index). Technological process of smoothing with
hardening applied to the gray cast iron with
lamellar graphite falls well within the limits
by
determined by the material properties and
particularly aims the quality improvement
exposed surfaces by smoothing roughness and
auxiliary the strengthening of the material on
active surfaces of parts.
3. THE GENERAL PROCEDURE
APPLIED TO THE NUMERICAL
SIMULATIONS
Numerical simulations follow a similar
procedure to all the scientific approach, which
consists in passing by several steps:
Step I - For the analyzed phenomenon building a
physical model, which highlights the main laws
that govern them. The case is the elastic plastic
solid medium, sometimes with viscous
component.
Step II - The mathematical model is established
based on the regularities that govern the physical
model using some simplifications and
assumptions. The mathematical model is
expressed by governing equations and a initial
and boundary conditions. Governing equations
can be sets of ordinary differential equations or
partial differential equations, integral equations
or other forms of equations, reflecting laws who
stood the formulation of the physical model.
Step III - Making meshing model - in terms both
aspects, geometric and mathematical, concerns to
the continuous domain transforming of definition
to the problem in a discrete domain and of the
governing differential equations or integrals
equations in algebraic form.
Step IV - Coding - this consists in passing of the
meshing model and of the calculation algorithms
in computer code, using a programming
language.
Step V - Numerical Solution - numerical solution
is obtained by solving in SOLVER - module - by
the output dataset.
3.1 PHYSICAL MODEL
Some materials, such as gray cast iron of a kind
used in the analyzed application in study, the
elastic domain is nonlinear. In these cases, for
simplifications, the elastic diagram it linearizes
and adopt a medium elastic modulus. For
materials with plastic deformations, in the
plasticize region of the characteristic diagram it
can be use the tangent modulus of plasticity, Et,
locally defined as the slope of the characteristic
curve (d /d ). Working metal by cold plastic
deformation, with low speed of deformation, but
bring a heating contribution that not lead to
significant increases in heat, so that all
coefficients that characterize the physical
properties of materials processed will be
considered that independents of temperature.
3.1.1 Plasticity. Constitutive differential
equations
Plastic deformation processes are irreversible,
bulk of the mechanical work of deformation is
transformed into heat. In plasticity, relationships
of this type are differential, but unintegrated.
Incremental approach of plasticity is made within
the theory of the plastic flow, in which
relationships are established between the growths
of infinitesimal deformations and stress and also
a number of status parameters plastic.
Assumptions of plastic flow are:
1. Deformable bodies are considered continuous
and isotropic;
2. Volume strain is strictly elastic and is
proportional to the mean stress ,
. (1)
Differential expression of this hypothesis is:
(2)
In relations (1) and (2) K is the volume modulus.
3. The total increments of the strain, , are
formed from increments of the elastic strains
and increments of the plastic strains, ,
(3)
Increments elastic strains are calculated using the
generalized Hooke's law,
, (4)
in which:
- are increments of the tensions;
G and - are elastic constants of the material;
– symbols of Kronecker.
4. The basic assumption of the theory of plastic
flow, with the link of proportionality between the
increments of plastic deformations and deviator
components of stress is given by,
, (5)
in which is an infinitesimal factor.
The energetic appearance of plastic deformation
is quantified by the plastic mechanical work, put
in the form incremented
, (6)
in which are the components of the principal
stresses and are the incremental components
of the plastic strains in the reference system
given by the principal directions of the stresses.
After substitution, in equations (5), relative to the
principal axes of the stress of the components of
the stress deviator expressed by principal stresses
with relations
(7)
and developing procedures, results the
expression of the incremental plastic mechanical
work, depending to the intensity of the stresses:
. (8)
Intensity of stresses or von Mises stresses has the
following developed expression:
. (9)
3.1.2 The structure of the physical model 3.1.3 Material models
For the numerical simulation is necessary to From the field investigations, the results
accomplish a complete model, that incorporates conclude that parts undergo to the plastic
the materials for processed and models of deformation process are made of gray cast iron
devices and active tools that come in contact with lamellar graphite. The plasticity of the gray
with the blank. Accomplishing physical model is cast iron with lamellar graphite in stress states in
determined by the shape and size of the bodies which prevails tractions is very low and therefore
involved in the process, by material properties, avoids the application of this method of plastic
especially of the blanks, and the regimes of deformation. The mechanical properties of the
work. In Fig.4 is essentialized a physical model gray cast iron with lamellar graphite are given in
for the expected technological process. the table 1.
Table no. 1. The mechanical characteristics of the gray
cast iron with lamellar graphite SR EN 1561:2012
Tensile Tensile Compressive Brinell
Class modulus strength strength hardness
[GPa] (min) [MPa] [MPa] [HB]
Fc10 70-90 160 400-500 120-187
Fc15 80-105 250 550-750 143-229
Fc20 90-115 280 600-830 156-285
Fc25 105-120 330 700-1000 170-302
Fc30 110-140 350 820-1200 187-321
Fc35 150-145 380 950-1400 207-321
Fc40 125-155 400 1100-1400 207-363

The characteristic diagrams, corrected using the

Fig. 4. The physical model for the technological process of procedure from Fig. 3 can be considered, with
cold plastic deformation sufficient precision the conventional
Simulated working regime’s parameters are: the characteristic diagrams of the material of
spindle speed of the machine, radial advance and samples, from the tested lot Fig. 6.
longitudinal advance. Speed remains constant
and the two advance movements it can correlate
to obtain the desired profile (CNC). In the
physical model, the longitudinal advance (axial)
is kept constant, following that the radially
advance to be adjusted according to the profile
sought. To achieve the major objectives of the
numerical simulation of the technological
process of plastic deformation, will be
incorporated into the physical module, bodies
with three types of surfaces: cylindrical, conical
and profiled shape Fig. 5

Fig. 6. Conventional characteristic diagrams -

Compression test - Lot no. 1

3.1.4 Formulation of the material models

Fig. 5. Models for blanks
On the conventional characteristic diagrams,
stresses and strains are defined by reference to
the constant sizes (cross-sectional area of the
specimen and its original length). To give a real
character to the diagrams, the tension it redefines
by applied force reported to the amount of
instantaneous cross-sectional area and the strain
is obtained by reference to the length of the
instant reference.
In the Fig. 7, is presented an approximate
conversion way of the characteristic diagrams for
the compressive testing and the assumptions in
that are doing it.
Fig. 7. Conversion of the conventional diagram in the real
diagram
Conversion result is shown in Fig.8.
Fig. 8. Real characteristic diagrams - Compression test -
Lot no. 1
In the case of plastic strains, were built models of
material (with linear hardening; exponentially,
plastic Johnson-Cook, poly-linear plastic).
The models of the poly linear plastic, it only use
for numerical calculation, the approximation of
the plastic characteristic curve being made by a
polygonal line with several segments, defined by
points.
Fig. 9. The poly linear model of plastic material
overlapped over the plastic characteristic curve
3.1.5 Selection, verification and validation of
material model
For applications of the smoothing process
simulation with hardening of the gray cast iron,
FC10, it using only poly-linear model with the
data in the table accompanying Fig. 9. Model
checking is made even on the compression
specimens from which came the data, on the base
which were built - the specimen I, from tests lot
no.1 and specimen IX from the tests lot no. 2,
from which will be retained, for comparison, the
following data:
- maximum force: 45.13kN; 47.91kN;
- race to the maximum force: 5.2mm; 4.1mm;
- seating surface diameter: 10 mm;
- after the test: the average 11.2 mm.
Was reproduced, by numerical simulation, the
simplified test of compression for specimen I
from the lot no. 1
Fig. 10. The simulation of the compression test on
an axial symmetric model - Sample I - Lot no. 1
The static response of the sample simulated was
retained in the form of curve (stress - strain).
The stress-strain curves, for both numerical
simulation tests are shown in Fig. 11, together
with the real curves, which were recorded on the
testing machine.
Fig. 11. The material model improved. Numerical
simulation of the compression test
Determination of the friction coefficient was
achieved by repeated numerical simulations with
different friction coefficients, chosen in
ascending order, settling at 0.08. In the stresses
analysis, it finds the existence of some highly
concentrators of tension, placed on the borders of
the contact surfaces (edges), and they will create
the conditions for priming failure fracture. The
representations of the stress from Fig. 10,
anticipates the emergence of a sliding surfaces
oriented approximately at 45 from the specimen
axis. The specimen failure it occurs due to the
tension concentrator on the boundary. Thus, the
compression test gives only a lower of strain
threshold at break of the material. Dynamic
effects, such as the viscosity of the material, are
introduced into the calculation equation by the
coefficient C of the constitutive equation (10).
Dynamic component in the technological process
of the hardening by smoothing is minor;
achieving dynamic test is not justified. It was
preferred the method of acquiring data from the
available literature (for iron has been found value
C = 0.055, and the soft iron - Armco, C = 0.060
for the gray cast iron C = 0.06). The effect of
viscosity of the Johnson-Cook constitutive
equation ( ). The expression can be
approximately transposed, in the expression
Cowper-Symond . For the range of
the deformation speeds from 1s-1 to 1000 s-1
values were found: C=7200s-1 and p=3.32.
Highlighting the effect of material viscosity was
done by simulating the deformation of a single
finite element, while maintaining constant strain
rate.
Since the logarithmic deformation is expressed
(10)
in which l0 is the length of the initial reference
and l is the length at a time, to maintain constant
strain rate
, (11)
where v is the relative rate of the two opposite
sides of the element, it is necessary that the
relative strain rate, to vary in time after an
exponential law
. (12)
In relation (12), is the initial relative rate and
strain rate is considered in absolute size,
irrespective that the stress is compression.
Rate law (12) it proves useful for numerical
simulations. Material viscosity effect on the
dynamic response of the material, obtained by
numerical simulation for strain rates 1s-1, 10s-1,
100s-1 and 1000s-1 is presented in graphic form
in Fig. 12. Graphical representations of Fig. 12
are concretizations of the viscose-elastic-plastic
material model, for the gray cast irons used in the
structure of the glass processing systems.
Fig. 12. Constitutive models for gray cast iron in
dynamical deformation
4. BIBLIOGRAFIE
[1] L.M. Khachanov, Fundamentals of the
Theory of the Plasticity, Mir Publishers,
Moscow, 1974, pp. 48-106
[2] Bathe, K. J., Finite Element Procedures in
Engineering Analysis, Prentice-Hall (1982)
[3] Bathe, K. J., and Wilson, E. L., Numerical
Methods in Finite Element Analysis, Prentice-
Hall (1976)
[4] Bathe, K. J. and Dvorkin, E. N., "A
Continuum Mechanics Based Four Node Shell
Element for General Nonlinear Analysis", Int. J.
Computer-Aided Eng. and Software, Vol. 1, 77-
88 (1884)
[5] Cook, R. D., Concepts and Applications of
Finite Element Analysis, John Wiley and Sons,
Inc. (1974)
[6] Hallquist, J. O., "A Procedure for the
Simulation of Finite Deformation Contact-
Impact Problems by Finite Element Method",
University of California, Lawrence Livermore
National Laboratory, Rept. UCRL-52066 (1976)
[7] Johnson, G. R. and Cook, W. H., "A
constitutive Model and Data for Metals
Subjected to Large Strains, High Strain Rates
and High Temperatures", presented at the
Seventh International Symposium on Ballistics,
The Hague, The Netherlands, April (1983)