Virtual Lab-AFDEX

(Forging Simulation)

Assignment 1
AFDEX Tutorial 1-8 Practice Report

Assignment Submitted by

Name: Chitrasen Maharana

Bits Id: 201918BT588
Course Name: Manufacturing Processes
Course Id: ET ZC235

Work Integrated Learning Program

BIRLA Institute of technology and Science, Pilani
Hall Ticket
Booked Slots
Tutorial 1- Problem Statement

DOUBLE STAGE COLD FORGING PROCESS (2D)

Tutorial 1- Forging Simulation Result
Tutorial 1- Observation & Report

In this tutorial, i have learned how to simulate Double stage cold forging process (2D) and
observed following various parameters which helps to understand the forging process in
details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 1.100 8.151*10-9

Effective Strain 1.543 1.000*10-4

Von Mises Stress (MPa) 7.928*102 4.236*10-2

Principal Mean Stress(MPa) 2.333*102 -3.608*103

Nodal Velocity (mm/s) 2.466 8.953*10-1

Tutorial 2- Problem Statement

SINGLE STAGE COLD FORGING PROCESS (3D)

Tutorial 2- Forging Simulation Result
Tutorial 2- Observation & Report

In this tutorial, i have learned how to simulate Single stage cold forging process (3D) and
observed following various parameters which helps to understand the forging process in
details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 1.229 1.315*10-2

Effective Strain 3.418 1.000*10-4

Von Mises Stress (MPa) 9.471*102 2.297*10-6

Principal Mean Stress(MPa) -1.400*102 -2.204*103

Nodal Velocity (mm/s) 2.349 0

Tutorial 3- Problem Statement

AUTOMATIC MULTISTAGE HOT FORGING PROCESS (3D)

Tutorial 3- Forging Simulation Result
Tutorial 3- Observation & Report

In this tutorial, i have learned how to simulate Automatic multistage hot forging process
(3D) and observed following various parameters which helps to understand the forging
process in details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 5.838*101 6.199*10-2

Effective Strain 3.882 1.000*10-4

Von Mises Stress (MPa) 1.019*102 2.561*10-4

Principal Mean Stress(MPa) -5.546*101 -3.694*102

Nodal Velocity (mm/s) 2.589*102 0

Tutorial 4- Problem Statement

SINGLE STAGE PLATE FORGING PROCESS (3D)

Tutorial 4- Forging Simulation Result
Tutorial 4- Observation & Report

In this tutorial, i have learned how to simulate Single stage plate forging process (3D) and
observed following various parameters which helps to understand the forging process in
details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 5.412 7.546*10-3

Effective Strain 1.686 1.000*10-4

Von Mises Stress (MPa) 8.042*102 4.593

Principal Mean Stress(MPa) 3.010*102 -2.434*103

Nodal Velocity (mm/s) 9.303 1.784*10-2

Tutorial 5- Problem Statement

SINGLE STAGE EXTRUSION PROCESS (2D)

Tutorial 5- Forging Simulation Result
Tutorial 5- Observation & Report

In this tutorial, i have learned how to simulate Single stage extrusion process (2D) and
observed following various parameters which helps to understand the forging process in
details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 8.992*10-1 0

Effective Strain 1.359 7.012*10-3

Von Mises Stress (MPa) 7.706*102 2.037*10-11

Principal Mean Stress(MPa) 4.682*102 -2.446*103

Nodal Velocity (mm/s) 1.274 9.319*10-1

Tutorial 6- Problem Statement
ROLLING PROCESS (3D)
• A Magnesium slab (AZ31) of 150 mm length 40 mm width 20 mm thick is reduced into high
rolling mill to thickness of 14 mm. The radius of roller is 100 mm and rotational speed is 30
rpm. The coefficient of friction between roller and workpiece is 0.25. Working temperature
is 3500C
• Process Type-Isothermal
Tutorial 6- Forging Simulation Result
Tutorial 6- Observation & Report

In this tutorial, i have learned how to simulate Rolling process (3D) and observed following
various parameters which helps to understand the forging process in details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 0 0

Effective Strain 1.311 1.000*10-4

Von Mises Stress (MPa) 1.083*102 0

Principal Mean Stress(MPa) 0 0

Nodal Velocity (mm/s) 0 0

Tutorial 7- Problem Statement
DOUBLE STAGE HOT FORGING PROCESS WITH SLIDING DIE (2D)
Tutorial 7- Forging Simulation Result
Tutorial 7- Observation & Report

In this tutorial, i have learned how to simulate Double stage hot forging process with
sliding die (2D) and observed following various parameters which helps to understand the
forging process in details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 9.641*101 3.475*10-3

Effective Strain 1.809 1.000*10-4

Von Mises Stress (MPa) 1.493*103 1.220*10-1

Principal Mean Stress(MPa) 4.652*102 -8.501*102

Nodal Velocity (mm/s) 3.203*102 0

Tutorial 8- Problem Statement

SINGLE STAGE HOT FORGING OF PISTON HEAD WITH FLASH (3D)

Tutorial 8- Forging Simulation Result
Tutorial 8- Observation & Report

In this tutorial, i have learned how to simulate Single stage hot forging of piston head with
flash (3D) and observed following various parameters which helps to understand the forging
process in details

Parameter Maximum Value Minimum Value

Effective Strain Rate (/s) 1.475*103 5.502

Effective Strain 3.919 1.000*10-4

Von Mises Stress (MPa) 1.528*102 4.509*10-1

Principal Mean Stress(MPa) 2.861*101 -6.328*102

Nodal Velocity (mm/s) 5.145*103 0