2011 Spring UGM Presentation File Distribute

Design Environment for FORMing
Spring 2011 User’s Group Meeting

Naples, Florida
May 4 & 5, 2011
UGM Agenda
♦ May 4, 2011
• 10:30 A DEFORM Activities

• 11:00 A Stan Wojciechowski, Alcoa Fastening Systems
• 11:30 A Victor H. Vazquez L., Consultores CPM SA de CV
» The application of DEFORM for Hot Stamping of Truck Axles and
Chassis Components
• 12:00 N Lunch
• 1:00 P Lorenzo Valente/Christian Viscardi, ECOTRE
» Hot Forging Aluminum and Brass
• 1:30 P Oliver Piek, Kistler-IGel
» Schondelmeier Application
• 2:00 P Steve Coryell, Special Metals – PCC Energy Group
» Modeling Requirements for Pilgering and Shape Rolling Processes
• 2:30 P James Farrar, Wilde Analysis
UGM Agenda
♦ May 4, 2011
• 3:00 P Coffee Break

• 3:30 P Q&A
• 4:00 P DEFORM Applications & Demo
• 5:40 P Dinner Cruise – Naples Princess
UGM Agenda
♦ May 5, 2011
• 7:30 A Continental Breakfast

• 8:00 A DEFORM System Current Development
• 9:45 A Coffee Break
• 10:15 A DEFORM System Future Development
• 12:00 N Lunch
• 1:00 P Adjourn
Major Activities Since 11/3/2010
♦ UG Meeting
53 people from 34 companies (11/3-4/2010)
♦ Program Release
• DEFORMTM -V10.2 (beta1) (04/11)
♦ Program Enhancements
• DEFORMTM –V11.0
♦ Active Projects
• SBIR, STTR, MAI, FAST
♦ System & Service Delivery
System & Service Delivery
♦ Supported Platforms & Compilers

♦ License Manager
♦ E mail (support@deform.com)
♦ Web Site (www.deform.com)
♦ DEFORM News
TM
Supported Platforms/Compilers
♦ Operating Systems Compilers

• Windows XP, Vista, Win7 Absoft f90 v9.0, v11.0
• HP-UX 11.11 (limited support) HP/FORTRAN S700 B.11.01.20
• HP-UX 11.23 (limited support) HP/FORTRAN S700
• Centos Linux 2.6.9.100 (Centos 4.7) Absoft f90 v10.0 (64 bit)
• Centos Linux 2.6.18.238 (Centos 5.6) Absoft f90 v11.0 (64 bit)
• Linux 2.6.9-42.3sp.XCsmp (limited support) Absoft f90 v10.0 (64 bit)
• Suse92 Linux 2.6.8-24.25 (limited support) Absoft f90 v9.0 (32 bit)
• Suse Linux 2.6.32-29 (Suse11) Absoft f90 v11.0 (64 bit)
Note:
1. Deform 2D and 3D products released on Centos Linux 2.6.9-100 and 2.6.18.238 are
recommended for Redhat Enterprise Linux 4 and Redhat Enterprise Linux 5 respectively
2. Linux 2.6.9-42.3spXCsmp is the recommended pack for the Cluster version
3. From DEFORM v10.2, 64 bit FEM support is available on Centos Linux 2.6.9-100 (Centos
4.7), Centos Linux 2.6.18-238 (Centos 5.6), Suse Linux 2.6.24-25 (Suse11) and PC
4. 64 bit user routine support is not available with Absoft f90 v9.0
5. Absoft f90 v11.0 is used for system builds from DEFORM v10.2.
6. User routine support on PC with Absoft f90 v7.0 and v7.5 has been discontinued from
DEFORM v10.2.
7. Microsoft has discontinued their XP support in 2009.
SFTC DEFORM Team TM
Dr. Alexander Bandar (ABandar@deform.com) Material Model

Dr. Pavanachand Chigurupati QC, System Release
(PChigurupati@deform.com)
Dr. Hyunjoong Cho (HCho@deform.com) GUI & Support
Dr. Byung Kwan Chun (Bchun@deform.com) FEM & Process Model
Ms. Misty Engelbrecht License Administration
(MEngelbrecht@deform.com)
Mr. Tom Feister (TFeister@deform.com) Applications & Support
Dr. Christian Fischer (CFischer@deform.com) Machining Model & Support
Mr. Michael Foster (MFoster@deform.com) Applications & Support
Mr. Timothy Hanes (Thanes@deform.com) Pre, Post & GUI
Mr. Paul Hostetler (PHostetler@deform.com) Sys. Admin. & Support
Dr. Jong-Tae Jinn (JJinn@deform.com) FEM & Process Model
Dr. Deepu Joseph (DJoseph@deform.com) FEM & Process Model
Mr. Won-Jeon Kim (WKim@deform.com) Pre, Post & GUI
Dr. Weiqi Luo (WLuo@deform.com) GUI & Material Model, License
Mr. Jim Miller (JMiller@deform.com) Sales and Marketing
Dr. Jin Yong Oh (JOh@deform.com) Systems & GUI
SFTC DEFORM Team TM
Mr. Harigopal Polisetty (HPolisetty@deform.com) Pre, Post & GUI

Mr. Ravi Shankar (Rshankar@deform.com) Projects & Mktg
Dr. Guang Sheng (GSheng@deform.com) Material Model
Dr. Juipeng Tang (JTang@deform.com) System Integration
Mr. John Walters (JWalters@deform.com) Mktg & Consulting
Mr. Pihui Wei (PWei@deform.com) Pre, Post & GUI, License
Ms. Nancy Welling (NWelling@deform.com) UG Coordination
Dr. Wei-Tsu Wu (WWu@deform.com) Technical Development
Dr. Zhuang Wu (ZWu@deform.com) Pre, Post & GUI
Dr. Jaebong Yang (JYang@deform.com) FEM & Process Model
Dr. Jixi Zhang (JZhang@deform.com) FEM & Material Model
Dr. Lei Zhang (LZhang@deform.com) FEM & Process Model
Prof. Soo-Ik Oh Senior Advisor

Mr. Guoji Li Consultant
SFTC Staffing Plan
♦ Staff members with strong background in FEM & Metal forming

Processes.
♦ Staff members with strong background in Material Modeling.

UG Meeting (Tentative)
♦ November 8-9, 2011 @ Columbus, OH

System Updates
Selected System Updates
3D V10.2
♦ Memory leak issue with 64 bit FEM engine (reported in v10.1sp2

Linux version) has been addressed.
♦ One consolidated FEM engine (one 32 bits and one 64 bits) now
replaces the one CPU and MPI components.
♦ 64 bit FEM3D user routine support is now available on PC,
Centos4, Centos5 and Suse11.
♦ System semaphore and shared memory segment clean up has
been improved for Linux operating systems.
♦ Patran files (.PAT) can now be directly imported in to 3D
Preprocessor
♦ More details will be available in release notes
System Updates
V11 Beta
♦ 2D Multi-frequencies Induction Heating

♦ Importing 2D database results into ring rolling models
♦ New Integrated machining distortion module (MAI-GE7)
♦ Mesoscale Microstructure modeling (SBIR-U720 Ingot Conversion)
♦ Elasto-plastic torsion model
♦ Improved geometry tool including basic morphing techniques and parametric modeling concepts
♦ Parallel Solid meshing
♦ Next generation of MO
♦ Next Generation of Post-processor
♦ Austenite Decomposition Model
♦ Improved extrusion model
♦ 3D resistance heating
♦ Improved Rolling Model
♦ Optimization
♦ Consolidated User’s routine*
* Ongoing effort
Dual Frequency Induction Heating
Hot Switching Combined
Hot Switching Dual Frequency System which 2 frequencies are switched at speed
of several micro-second
Dual Frequency Combined System
Ring Rolling
Import 2D Results
Extract geometry from imported object
2D cross-section view in 3D
Messages: object is loaded
Allow import objects from 2D DB

Ring Rolling
Import 2D to 3D
Punched
Conversion also takes care of

2D cross-section mesh window
Elasto-Plastic Torsion Model
Shear Stress distribution
Radiu
s direct 80
ion
Exact Solution (before yielding)
DEFORM v10(before yielding)
Shear Stress
Exact Solution (after yielding)
60 DEFORM v10(after yielding)
Shear Stress (Ksi)

Elastic
(a) loading 1 (before yielding,t=3sec) 40
Plastic
20
Radiu
s direct 0
ion
0 0.2 0.4 0.6 0.8 1
Radius (in)
Shear Stress
(b) Loading 2 (after yielding,t=10sec)

Parameterized Geometry Features
GEO-Tool Morphing
Target 1 Target 2
Larger diameter (1) Larger diameter (2)
Source
Original
Target 3 Target 4
wider longer
Parallel Global Remeshing
Remesh Time (Extended Memory Allocation)
Processors
1 2 3 4
50 13 20 16 17
Number
Of
Elements
100 19 18 21 21
(K)
300 49 39 35 36
600 101 71 59 57
1200 201 143 117 111
Meshvol.inp.par
TEST
Text string
Max. possible Boundary nodes 400000 3000000
Max. possible Domain nodes
Mesoscale Microstructure Modeling
•Extended to 2D
Flow Stress Model is a function of
•Point tracking recrystallization and dislocation density
•Interpolation across remeshing 1 1
σ f = σ 0 + ( X init )(αGbρ ) 2 + ( X DRX )(αGb ) 2
•Improved state variable display
Flow Stress as a
Dislocation function of
Density dislocation
D0 = 12 µm D1 = 6.1 µm D1 = 4.5 µm D1 = 0.02 µm
density
System Updates
V11 Beta+
♦ Spin Model
♦ Probabilistic Material Model
♦ Process-lifing Integration Model
♦ 3D texture Model
♦ SPF Model
Project Work
Probabilistic Prediction of Location-Specific
Microstructure in Turbine Disks – Phase I
Office of Naval Research STTR Contract: N00014-10-M-0264

Program Manager: Dr. David Shifler
Modeling Spin Testing Using Location
Specific Material Properties – Phase I
Air Force STTR Contract: FA9550-09-C-0056

Program Manager: Dr. Joan Fuller
Integrated Processing and Probabilistic Lifing
Models for Superalloy Turbine Disks -
Phase I
Air Force SBIR Contract: FA8650-10-M-5110
Program Manager: Dr. Rollie Dutton

Integrated Multiple Operation
(The Next Generation)

Introduction
♦ Integrated Multiple Operation (MO)

• There are growing interest to understand complete manufacturing process
from raw material to final product
• The next generation MO will be an integrated form of all the current
templates
♦ Platform for future simulation trends

• Nowadays, running multiple simulation of MO is becoming common
• The next generation MO will be a platform for parametric study, DOE study and
optimization
Integrated Process Modeling
System
Geometry Microstructure Properties Residual Stress

Anomalies
Cogging Forging Heat Treat Machining Spin

Lifing
Cogging Shape Cooling Machining Mission

Sequence Ram Speed Rate Sequences Cycles
Alloy
DOE
Composition
Design Optimization
Scope Of Work
♦ Restructure existing MO, Cogging, Heat treatment,

Machining, Machining Distortion, Rolling, Ring Rolling, etc
• Unified, integratable, reusable
• Possibly replacing the existing GUI-PRE
• Open structure for other software to interface
♦ DOE Infrastructure
• Sensitivity study to address variabilities in processing conditions,
material data and boundary conditions
• Post-processing the DOE result
♦ Optimization
• Process optimization, Shape Optimization, Inverse calculation
• Parallel computing
Integrated Manufacturing
Processes
• Forming
• Heat treatment
• Welding/Joining
• Machining
• Service
• Lifing
Forming Operations
• Multiple Forming processes

• Cogging
• Forging (Energy based)
• Forging Express (Energy based, F2/F3)
• Shape Roll
• Single Forming process

• Forging
• Forging Express (F2/F3)
• Extrusion
• Ring Rolling
• Flow Forming
Heat Transfer Operation
• Heat Transfer Operation

• Heat Transfer (Air Convection)
• Heat Resting (Before forming)
• Heat Dwelling (After Forming)
• Induction Heating
• Resistance Heating
• Furnace Heating
• Batch furnace
– Thermal schedule, PID and Fan etc.
• Load pattern
• Furnace Heating Express
Heat Treat Operations
• Multiple heat up/cool down

o HT Wizard
Deformation, diffusion, phase
transformation
o HT Express T
Heat transfer only: temperature,
time
Heating Carburizing
• Single heat up/cool down Temp3, Atom%
soak3
o HT Carburizing Temp2,
Atom% soak2
Temp1,
Surface reaction coefficient soak1
o HT Quenching
HTC Tempering
TTT TTT, σ vs. ε
Deformation
o HT Tempering
TTT or others
Deformation
0 TTT, σ vs. ε
Quenching
t
Machining Operations
• Multiple Machining Operations

• Machining Distortion
• Single Machining Operation

• Machining Distortion
• Turning
• Milling
• Boring
• Drilling
Simulation Operations
• 2D to 3D conversion
• Flipping
• Copy/Mirroring
• Boolean
• Remeshing
• Die Stress
• Report generation
Key features
♦ Fast input preparation

• System defined libraries, templates
• User configurable - customized libraries
• Turbo input mode (no opening and closing operation)
♦ Flexible operation handling
• Graphical handling of re-order, cycle
• Copy/paste/delete function
♦ Powerful modification scheme
• Simplified object/material replacement
• Changing lubricant condition for all operation
• Easy-to-use modifiers
User Interface (1)
Overview
Graphics Tree
Explorer
Manager Operation Editor Property

User Interface (2)
Explorer
♦ Explorer Types
• Operation explorer
• Object explorer
• Material explorer
• Equipment explorer
• Lubricant explorer
♦ User templates
• Setup similar simulation can be done quickly
through customizable template
♦ User library
• User’s item can be registered as user library
for future use
User Interface (3)
Manager
♦ Manager Types
• Operation manager
• Object manager
• Material manager
• Equipment manager
• Lubricant manager
♦ Items are managed by Manager

• Each item will receive an <id>
• Each operation will keep the <id>s
♦ By using <id> concept, we can easily

replaced an existing item with new
item later
User Interface (4)
Editor
♦ Operation editor provides an graphical environment to browse and
to edit multiple operations
• Different operations can be connected (integrated) together
• Changing orders, inserting or deleting operations are simple
• Drag-and-drop method are supported
• How an object will be passed to the next operation is obvious
User Interface (5)
Property
♦ Property editor provides a concise
summary of the important input data
♦ It will be useful to check input data or

to modify them quickly across many
operations
Sub-Project Concept
♦ One MO project can have multiple sub-

projects
♦ Sub-projects can have some variance
♦ Parametric study, DOE study is just one
mouse click away !
Demonstration
Heat Treat Model
(Next Generation)
Heat Treat Model- Overview

• [M] HT Wizard
• Deformation, diffusion, phase
transformation
• [M] HT Express
• Heat transfer only: temperature, time
• Single heat up/cool down
• HT Carburizing T
• Atom%
• Surface reaction coefficient Heating Carburizing
Temp3, Atom%
• HT Quenching soak3
Temp2,
• HTC soak2
Temp1,
• TTT soak1
• Deformation
• HT Tempering Tempering
• TTT TTT, σ vs. ε
• Deformation
0 TTT, σ vs. ε
Quenching
t
Heat Treat Model
Outline
• Overview
• [M] HT Wizard
• [M] HT Express
• Single heat up/cool down
• HT Carburizing
• HT Quenching
• HT Tempering
• Summary
Problem Setup
HT Express Carburization Quenching Tempering
o t
[M] HT Express
• Multiple Heat Transfer Operations

• Global Heat Transfer Environment
(Uniform Settings)
• Temperature
• Heat transfer coefficient
Heating
T Temp3,
Temp2, soak3
soak2
Temp1,
soak1
0 t
[M] HT Wizard
• Compatible to previous HT
Wizard
• Deformation, diffusion and phase
transformation
• Global and Local Heat Transfer
Environment (Location
Dependent, Non-uniform
settings)
Summary
• QT4 based
• Predefined HT process help quickly set up heat treatment
simulation for all purpose
• [M] HT Wizard
• [M] HT Express
• [S] HT Carburizing
• [S] HT Quenching
• [S] HT Tempering
• Easily customize a process and reuse it
• Integratable with other processes in new MO
Furnace model
Furnace Model
Outline
• Furnace model: HT Batch Furnace

• Furnace model basic
• Keywords
• GUI interface
• Summary
• Appendix
Furnace Modeling
Introduction
Thermal
schedule
T.C.
Heat Recirculation fan
source
Workpiece
Stacked
Fixtures PID controller
Cooling
Water
furnace wall
*Assumptions:
• Uniform furnace temperature
Furnace Modeling
Heat Balance
Heat flow in furnace: Load in a heat treating furnace:
qfan mass Parts

qheat-input • Fixture/tray
qstorage • Grate
• Firing-ring
Accessories • Fan
• Roller rail
qcool qloss • Heating Element
qload Insulation wall
N
∂ Ti
Energy Balance q _storage = ∑ ( ρ i ⋅ c pi ⋅ V ) ⋅
Equation: i =1 ∂t
q _mstorage ⋅ ∆ t
∆ T_ fce = N
∑ (ρ
i =1
i ⋅ c pi ⋅ Vi )
HT Batch Furnace
ENVTMP of Furnace Function
ENVTMP 10, Ndata

----------------------------------------------------------------------------------------------------------------------------------
1., GFDim1, Ftype1, Nset1, Ndim1
1,Data1(1,1), Data1(2,1), …, Data1(Ndim1,1)
...
Nset1 ,Data(1,Ndata1), Data(2, Ndata1), …, Data(Ndim1, Ndata1)
…
Ndata., GFDimN, FtypeN, NsetN, NdimN

...
----------------------------------------------------------------------------------------------------------------------------------
OPERAND DESCRIPTION DEFAULT
Ndata Number of data sections for furnace definition 20
GFDimN Section function dimension of section N 1
FtypeN Function type of section N 0
NsetN Number of data pairs to define function None
NdimN Dimension of data array of the function None
DataN(I,J), …, DataN(I,J) Data sets of the function of section N None
DEFINITION The environment temperature is used in radiation and convection heat transfer calculations and represents the
room temperature of the area in which the manufacturing process is taking place.
REMARKS
• The environment temperature may be specified as a constant value or as a set of discrete time/temperature pairs, or even calculated by defining furnace parameters.
• If Ftype = 0 use the operand Etemp.
• If Ftype = 1 use the operands Ndata, Time(i), Etemp(i). Each time/temperature pair should be provided on a separate line. When process time lies within the specified data range, linear interpolation
is used to determine the environment temperature. When process time lies outside the specified data range, linear extrapolation is used to determine the environment temperature.
• If Ftype = 2 use the operands Ndata, FtypeN, NsetN, NdimN, DataN(i,j). Total Ndata of sections are defined for furnace definition. And each section should be provided in NsetN lines of NdimN data
values
Environment temperature as
function of furnace
General Settings
IFSHAP
Section 1 - general:
1, 1, 0, 2, 6
1, IHTSCR, ISVAC, IFSHAP, HINT,
FUREF, SCALE OVH/OVW
2, NUMOBJ, NUMWAL, NUMLAY,
NUMACC, NGRIDS, NTPAIR
Section 3 - geometry data of furnace: OVL

3, 1, 0, 1, 6
1,OVH, OVW, OVL, WORKH, WORKW,
WORKL
HINT
Section 5 ¨C combustion parameters:
5, 1, 0, 2, 6 IHTSCR
1, IFUEL, HTCNT,COMTMP, EXCAIR,
A_G_RATIO, 0.0 IFUEL
2, A11, A12, A13,A21, A22, A23 COMTMP
EXCAIR
function of furnace
Wall Settings
NUMWAL
Section 1 - general:
1, 1, 0, 2, 6
1, IHTSCR, ISVAC, IFSHAP, HINT, FUREF, SCALE
2, NUMOBJ, NUMWAL, NUMLAY, NUMACC,
NGRIDS, NTPAIR
Section 16 - number of layers of furnace wall :

16, 1, 0, NUMWAL, 1
1, nLayers(1) NUMLAY
¡-
NUMWAL , nLayers(NUMWAL)
Work Space Atmosphere

Cooling system
Layer 1 Layer n
Tshell ≈ Toutlet
Qwall ≈ 0
∂T ∂T
ρcV = −kA − q&cool
∂t ∂n Cooling as heat sink
(
q&cool = Iratew ρ wcw Ti − Tinlet )
function of furnace
Cooling System
Section 6 - cooling system: OPENA

6, 1, 0, 2, 3
1, OPENA, FAI, ALT SHCRT
2, SHCRT, SHCIN, SHCOT SHCIN
SHCOT
function of furnace
Fan System
iFFMAT
Section 7 - fan/blower:
7, 1, 0, 3, 8
1, IFFMTR ,IFFLOC, IFFONFF, FFHP, IFFMTR
FFSPD, FFDIA, FFHIGH , FFWGT
2, FFCWRT, FFCWIN, FFCWOT, FFHP
CONST1, CONST2, 0.0, 0.0, 0.0
3,iFFMAT, NFANThrcnd, NFANHeatcp, FFSPD
NFANEmsvty, NFANDensy, 0.0, 0.0, 0.0
FFDIA
FFHIGH
FFWGT
*Notes – material section FFCWRT

NFANThrcnd – Section No. of
FFCWIN
the material data defined
FFCWOT
function of furnace
Accessory
NUMACC
Section 15 - material number of furnace

iMatNo ACCWeight
accessories :
15, 1, 0, NUMACC, 6
1, iMatNo(1),
ACCWeight(1),NAccThrcnd(1),
NAccHeatcp(1), NAccEmsvty(1),
NAccDensy(1)
¡-
NUMACC, iMatNo(NUMACC),
ACCWeight(NUMACC),NAccThrcnd(N
UMACC), NAccHeatcp(NUMACC),
NAccEmsvty(NUMACC),
NAccDensy(NUMACC)
function of furnace
Thermal Schedule
Section 4 - PID parameters:

4, 1, 0, 1, 5
1, IONOFF, PGAIN, IGAIN, SPAN,
DAMP
Section 11 - thermal schedule,

time/temperature data pairs:
11, 1, 1, NTPAIR, 1
time(1), Stemp(1) IONOFF
¡- SPAN
time(NTPAIR), Stemp(NTPAIR)
PGAIN
IGAIN
DAMP
Furnace Library
~\Program
Files\SFTC\DEFORM\vxx.x
o MaterialLibrary
o PressLibrary
o FurnaceLibrary
Fuel
SCALE
Wall
Atmosphere Import
Accessory
Load Pattern
• Load pattern will be

only generated and
written to DB at final • For
step Workpiece
• Preview is available
• For Fixture
Object Definition of Load Pattern
• Object types • Workpiece:

• Solid • Solid, geo
• Virtual with mesh
Fixture:
• Solid
• Virtual, no geometry, no mesh,
only for energy calculation
Energy and temperature plot of
furnace modeling
• 64 objects
• 1/8 symmetrical
• View factors
• Heat flux to load
• Furnace energy
consumption
• P.I.D behavior
• Less than one hour
CPU time (i7)
Summary
•Developed
• Development of QT4 based HT Batch Furnace process with following features
• Vacuum, or atmosphere
• Electric, and gas furnace
• Energy consumption calculation
• PID control algorithm
• New furnace FE model predicts temperature more realistically for multi-load conditions
taking into consideration energy consumption
• Integratable with other processes in new MO.
•Future Work
• Forced convection formula along with load pattern
• Door open / Door close
Updates on
the Next Generation
Post-processor
Objectives
♦ Easy to handle multiple databases

♦ Flexible to incorporate text, image and graph
♦ Interactive and Batched
♦ Keep previous settings
♦ Record and reuse the sequences
♦ Automated report generation
♦ Customized report content/format
Key Features
♦ Smarter Post-processor
• Session concept – reusable for different database
• Supporting script - automate repeated tasks
• Undo/redo framework
♦ Better Post-processor
• Power-point style labeling
• Enhanced graph plot
• Enhanced slicing
• Flexible layouts
• Picture in picture (PIP) mode
♦ Feature-rich Prost-processor
• Supports 3D mouse (3Dconnextion)
• Provides batch mode
• (continue on next slide)
New Features
♦ Batch state variable plot

♦ Batch graph (load-stroke) plot
♦ Batch summary plot
♦ Batch data extraction
♦ 3D PDF creation function
♦ Enhanced viewport handling
♦ Being developed
• Batch contact plot
• Batch under-fill detection
• Batch fold detection
Batch report preparation (1)
♦ Report file format

• Report file is an XML file with .DS extension – which can be expendable
• One report may have multiple chapters
• Each chapter will save descriptions as shown below;
– DB name
– Step Number
– View parameters
– Slicing information
– Display items (location, size and specific settings)
– Etc
♦ Predefined chapter types

• User-defined
• State variable
• Graph (Load-Stroke) data
• Summary data
• Analysis : fold detection / contact plot / under-fill
♦ Chapter browser
• Predefined chapter can be added (with or without database)
• Enables viewing and loading sessions
• Provides preview screen
♦ Create chapter
♦ Navigate chapters
♦ Batch data extraction

• Now multiple data extraction can be defined (with or without database)
• State Variables
• Graph (Load-Stroke) data
• Summary data
• Etc
Enhanced DB management (1)
♦ Home directory handling

• Provides navigators
• Provides auto completion
♦ Search function
• Regular expression (for example, Project*.db, *_2010.db)
• Search sub folders
Enhanced DB management (2)
♦ Various view modes

• Supports problem-tree view and icon view
♦ Preview function
• Shows thumbnail image of database or session
• Supports session preview
Highlighted Features (1)
Undo-Redo
♦ Object on/off
♦ Color bar on/off
♦ DB loading/unloading
♦ Move item
♦ Resize item
♦ Etc
Script
Load DB
Object turn on/off
Plot Load Stroke
script_test_no_db.txt
Flexible Layout
♦ PIP and item concept make flexible layout possible
Enhanced Summary Graph
♦ Multiple summary graphs can be shown together
Histogram on Slicing Planes
♦ State variable distribution for each slicing planes can be shown as
histogram
Enhanced Slicing
♦ On-screen controls to modify slicing plane
♦ Separate display item for showing slicing curve
♦ Multiple slicing curves can be displayed
3D Mouse Support
♦ 3D mouse function is available : supports 3Dconnexion mouse
♦ Provides simple and fast manipulation
• Panning / Spinning / Zooming
Pan Right/Left Zoom Pan Up/Down
Tilt Roll Spin
Picture Source : 3Dconnextion

Enhanced Viewport Handling
♦ Walk-in mode
♦ Dynamically changeable rotation center
3D PDF Support
♦ Now, report can include 3D Model in PDF file
• Different rendering modes and object controls
• Provides various predefined views
Model Toolbar
Tree
Predefined
views
3D PDF file loaded in PDF Viewer

Batch Mode
♦ Report can be generated in batch mode from DB files and DS file.
♦ DEF_GUI_PST.INI
DBNAME 1
IDS_Link_const_speed.DB
DSREAD
test-demo.ds
OUTPUT 1
demo.pdf
OUTPUT 2
demo.ppt
GENRPT
DONE
Brief Summary
Expected Benefits
♦ Automated report generation
• PDF file generation (including 3D model)
• Power-point file generation
• Generating one report from multiple simulation DBs (*)
– Creating response surface for DOE study
♦ Shortened post-processing time

• Remembering previous status
• Reduce repeated series of mouse clicks
♦ Excellent database management

• Good for comparing different simulation results
• Easy to search / manage databases
Demonstration
Shape and Process
Optimization
3D Shape Optimization
Approach
♦ Parallel run Input Data
♦ Morphing
♦ Meta-model Generate Initial
design points
Applications
Function Generate Next
♦ Preform design in York forging evaluation design points
♦ Die design in wire drawing process
♦ Die design in stress analysis N Update Meta-Model
Optimum ?
for Objective function
Y
Stop
Preform Optimization
♦ York Forging process

♦ Preform shape optimization
♦ Objective function
• Workpiece volume
♦ Constraint
• Fold and die fill
courtesy of American Axle and Manufacturing

Workpiece Shape
L
Source geometry
D
W H
1st parameter geometry (L)
2nd parameter geometry (W)
3rd parameter geometry (H)
4th parameter geometry (D)

Constraint function
Die fill
Non contact Under fill
Fold
Fold
Initial design
Design parameter (0, 0, 0, 0)

Initial design
Design parameter (1, 1, 1, 1)

Failed case
Design parameter (0.25, 0.5, 1, 0)

Optimum design
Design parameter (0.63, 0.63, 0.55, 0.45)

Optimization result
Windows vista with 4 core

120 simulations
7.5 days
Minimum workpiece volume

1.081 x 10-3 m3
Drawing die shape optimization
♦ Drawing analysis
♦ Objective function is difference of
max. effective strain and min. effective Wire
strain. φ = 5.5
♦ Design variable is die shape.
♦ Al-1000
♦ ALE simulation
♦ 1/4 model
♦ wire diameter 5.5mm Drawing die
V=10mm/sec
Drawing die
Initial die shape

L=4
D = 5.2
Die profile = line
Geometry for 2nd parameter D = 7
Geometry for
1st parameter
L=6
Geometry for 3rd parameter

die profile = Sine curve
Optimization result
Optimum die shape Windows vista with 4 core

with parameter (1.0, 0.0, 0.94)
60 simulations
12.5 hours
Effective strain
Die stress analysis
♦ Die stress analysis

♦ Objective is to minimize the
maximum die stress Outer die
♦ Design variable is die shape.
♦ Nodal force is interpolated from

final step of forging process. top die
♦ Multiple die shape change.
bottom die
Bottom die
Geometry for 1st parameter H (22)
D
Initial die shape H=18, D=20
18 < H < 22
20 < D < 22
Geometry for 2nd parameter D (22)

Top and outer die
Initial geometry Geometry Geometry

for 1st parameter for 2nd parameter
Top die
Outer die
Die shape
Die shape with parameter (0.0, 0.0) Die shape with parameter (1.0, 1.0)
Optimization result
Optimum design with parameter (0.21, 1.0) Windows vista with 4 core
H = 18.84, D = 22.0 60 simulations
2 hours
Effective stress
Initial design Optimum design

Optimal Heat treat condition to
achieve a target residual
stress
Process Optimization
Objective - to achieve desirable residual

stresses at specified locations by varying
heat treatment condition
Methodology
♦ Heat transfer coefficient inverse optimization
♦ Objective is to minimize the difference of
residual stress between target and
simulation result.
Current Example
♦ Includes heat treat and machining process
♦ Titanium alloy
♦ Elastic-plastic elements
Objective function
Objective function P3 σr = −181

P6 σr = 53
1
∑ (σ FEM − σ EXP )
2 P4 σz = −155
f =
N P5 σz = 78
P1 σθ = 86
P2 σθ = 6
σFEM : stress from FEM solution
σEXP : target stress value
N : number of points
Target stress
Heat transfer coefficient
♦ Inner and out surface heat transfer

zone
♦ Convection coefficient is function
of time
♦ Each function has 5 design points
Outer
surface
zone
Inner surface
zone
Initial Design
Optimization result
outer surface
inner surface
Stress value
Summary
♦ 3D shape optimization was developed

♦ Morphing technique was used for design change
♦ Optimization program is used for Preform and Die design in metal forming
process
♦ It is also used for die design in stress analysis
♦ Optimization can be used to design the cooling rate to achieve a desirable

residual stress
Austenite Decomposition Model
During Quench for Common Steels
Objectives
•Develop multiphase austenite decomposition kinetics model for

quenching of ferrous material, with composition effects
•Can be used to compute the required phase transformation data

for the quenching simulation
•Can be incorporated within FEM by defining chemical composition

distribution
Thermal-mechanical-
microstructure model
Thermal Deformation
σ ,ε
Adiabatic Heating
T Tr
Thermal Expansion
/ P a n Ph n
re sfo as i c ti o
ci rm e am iza
l n
La pi a
ta ti yn tal t io
te ti on D s a
n on ry r m ity
t
H ec fo tic
ea R s s
t r a n la
T P
Microstructure
µ
Process-Structure-
Properties
•Thermal-mechanical loading
•Thermal-Mechanical Boundary
Process Condition
T
Chemical
Component
t Compositions
Performance
•Phase Volume fraction Properties •Phase Diagram

•Grain size
Structure •Phase
Transformation
•Precipitate size
•Hardness
•Etc.
•Strength
•Etc.
Physical Metallurgy of Austenite
Decomposition in Quench
ferrite bainite
T S.T.
t
Scope of the Work
1. Model requirements
• Purpose of the model — 1) TTT/CCT curves, 2) FEM integration
• Modeling transformation into ferrite, pearlite, bainite and martensite; ignoring detailed
distinction by phase morphology
• State-variable form to compute volume fraction evolution :
Share common block (also contains some calculated-once variables)

State variables (and others)
FEM variables
∆f i ( X j , G, f i , Tn , Tn +1 , ∆t n→n +1 )
for i = ferrite, pearlite, bainite and martensite
X j : concentrations of alloy compositions, G : grain size
Tn , Tn +1 , ∆t n→n +1 : linear starting/ending temperatures, and time duration
2. 20 steel compositions selected for calibration and validation

1035, 1045, 1050, 1320, 3120, 3140
4027, 4037, 4130, 4140, 4340, 4330
5140, 8620, 8630, 9310
403 stainless, 410 stainless, 416 stainless, 430 stainless
Approaches
• Empirical analytical model to solve TTT curves
• Consider multiphase competition
• No additive rule
• Model can be parameterized to fit to experimental data if available
• Explore the use of CALPHAD databases
• Other mechanistic and detailed models, may require more

computational resources
Calibration and Validation
TTT-Ferrite-Start (T-Fs) CCT-Ferrite-Start (C-Fs)

TTT-Pearlite-Start (T-Ps) CCT-Pearlite-Start (C-Ps)
TTT-Bainite-Start (T-Bs) CCT-Bainite-Start (C-Bs)
TTT-Total-End (T-Te) CCT-Martensite-Start (C-Ms)
CCT-Total-End (C-Te)
Examples
T-Fs
T-Ps
C-Fs
C-Ps
T-Bs C-Bs
T-Te
C-Ms C-Te
Calibration and Validation
Experimental Diagram
All experimental data from Atlas of Time-Temperature Diagrams for Irons and Steels, ASM Handbook
Prediction
Four Preliminary User Adjustable
Parameters
Time Scaling Factor of 10 Temperature Shift Down 50°C
Original 8630
prediction
Fraction Scaling to shorten or Temperature Scaling of 0.5

broaden start and end curves
Summary and Future work
Summary:
• Preliminary model has been implemented and can be used in FEM code or
TTT/CCT curves generation
• Reasonable prediction for low alloy steels (<0.6C, <2Mn, <5Ni, <2Cr, <1Si)
• Preliminary user adjustable parameters available to fine tune the prediction
• This model has been calibrated and validated against following alloys:
1035, 1045, 1050, 1320, 3120, 3140
4027, 4037, 4130, 4140, 4340, 4330
5140, 8620, 8630, 9310
Future Work:
• Work on models parameters and predictions for stainless steels
• Improve implementation efficiency for spatially varying compositions
(carburization) and grain sizes
• Improve and widen composition ranges
• User friendly interface to tune TTT curves to better fit experimental results
3D Extrusion
3D EXTRUSION
•ALE Advantages
•Reduce frequent remeshing due to mesh distortion in extrusion simulations
•Fast Convergence
•Problem size not growing
•ALE Limitations
•Does not model the process of die cavity filling
•Does not model front flow of the extrudate
•Requirements
•Convection calculation for the evolution of state variables such as strain,
damage,temperature
•Boundary surface update
•Application of appropriate constraints to prevent node leaking related to singularity
Node Leaking
A node at a sharp die corner may

obtain very large values
for velocity (in tang direction to
extrusion) - “leaking”
Reasons:
•High Internal Pressure
•Insufficient constraints in the
tangential direction
•Typically happens at die corners
with one constraint,
corners with coarse elements
Remedy:
•Automatic application of
constraint.
•Geometry Feature
•Velocity Field Automatic detection of die corners and application
of double constraints
IMPACT BEAM PROBLEM
(Courtesy: Kyungnam Metal Co, Korea)
•Hot Extrusion
•Extrusion Ratio ~ 19
•Billet OD 180mm
•Ram Speed 2mm/s
•Aluminum
•Initial Temp:500C
•Flat die
•1/2 model
•306K Elements (ALE)
Workpiece
D. Joseph, J.Yang, J.Oh, M. Foster, W.Wu, J.Lim, K.Kim, S.Park, ”Aluminum Extrusion Simulation using
Finite Element Method”, Light Metal Age, ICEB 2011, Oct 3-5, Bologna, Italy
IMPACT BEAM
(Kyungnam Metal Co Ltd, Korea)
Extruded Aluminum Parts

Extruding Velocity and Profile
Slower Faster
ALE velocity profile and extrudate Real Extruded Product

shape
Velocity Profile along Cross-section
Extruding
vel
z
Velocity Profile along Cross-section
Average Extruding Velocity

Theoretical ~ 38 mm/s
(Based on Mass Conservation)
Computed:35 mm/s
60
50
Extruding velocity magnitude
40
Average
30
Maximum
Minimum
35mm/s
20
10
0
-200 -150 -100 -50 0 50 100 150 200
Z
Temperature Distribution
Steady State
ALE
Temperature starts at 500C

Increases locally by 20-30C
Updated Lagrangian
Effective Strain
SS
ALE
Steady State
ALE
Updated Lagrangian
Load Stroke Curve
400
SS
350
300 ALE
Load (SI tons)
250
200
150
100
UL
50
0
0 10 20 30 40 50 60 70 80
Stroke (mm)
UL –Filling up
Weld chamber
Max Temp= 500C 504C 506C 518C
ALE: Max temperature rises from 500C-528C in 0.5s

Die Fracture
Die Stress Analysis
Die Stress Analysis Model: 3 pieces, Material: AISI-H13
Mandrel-1piece
(actual process
has two pieces)
Ring
Die Stress Analysis
Determining Die Fracture Hotspots
Max Principal Stress distribution on the

Real Die
mandrel
Summary
•Improvements in robustness over previous versions
•Automated detection and application of constraints to prevent

node leaking; removes requirement of specifications through external files
•Future Work
•Further fine tuning for improved stability
•Validate with more industrial cases

Electric Resistance Heating
and Rolling Processes
Electric Properties of Metals
- Ohm’s law (Continuum form) E = ρJ

where "E" is the electric field vector [V/m] ( ~ analogous to "V" of Ohm's law which has units of volts),
"J" is the current density (flux) vector [A/m²] ( ~ analogous to "I" of Ohm's law which has units of amperes),
"ρ" is the resistivity [Ω-mm] ( ~ analogous to "R" of Ohm's law which has units of ohms).
- Electric resistivity:
E
ρ [Ω ⋅ mm]
L
I I
- Current flux:
where
I a
J = [ A / mm 2 ] I is the electric current [A]
a is the area [mm²]
J
a V
- Voltage (potential difference between two points) : Low-voltage high-ampere electric current
is defined by passes through metals and heat is
V L
E = [V / mm] E is the electric field vector [V/mm] generated by resistance, R R=ρ
L L is the length of conductor [mm] a
- Interface resistivity [Ω-mm² ] (between die and workpiece)

Integrated Process Simulation
Architecture
Q&
E
I
L I Thermal Deformation
σ ,ε
Adiabatic Heating
a
J
V
T Tr
Thermal Expansion
/ P a n Ph n
re sfo ase i c ti o
ci rm am iza
l n
La pi a
ta ti yn tal t io
te ti on D s a
n on ry r m ity
t
H ec fo tic
ea R s s
Applicable Processes t r a n la
T P
• Joining
Microstructure
• Rolling
• others µ
Status
♦ Electrical Resistance Welding of Ferrous sheets with phase

transformation has been modeled in 2009
♦ Both Graphical User interface and FEM implementation are
available in Beta 11
♦ Electrical Resistance rolling processes of Ti-AL sheet are modeled.
Electric
Electric circuit
circuit
Electric current (I)

+
Local heating Materials with Voltage (V)
in sheet Resistance (R)
Electric current is supplied through the center of roll

Case Study 1
(For demonstration only – not
a real process)
FE Model Setup
by Shape Rolling Template
Outer roll
Inner roll
Sheet
Stand #1 Stand #2
GUI Design for
3-D Electric Resistance Heating
- Simulation Controls dialog - Inter-Object Data Definition Dialogs
Heating BCC
- Material dialog
ρ [Ω ⋅ mm]
Electric resistivity Interface Resistivity [Ω-mm² ]
Simulation Conditions
- Sheet Dimensions Roll Speed

= 0.025 RPM
Initial thickness 6.5 mm = 0.002618 [rad/sec]
Final thickness 4.7 mm Tinner roll= 93 C
Width 150 mm
Touter roll= 650 C
Flow stress Ti-Al alloy
TTi-sheet= 315 C
Friction factor, m=0.25
Nodes: 4810
Elements: 3600
168.2 mm
195.2 mm
Electrical Properties
& Heating BCC
Electric resistivity of outer roll Applied voltage: +0.6 [V]
Electric resistivity of inner roll
Interface resistivity
between outer roll and sheet
0.0005 [Ω-mm² ]
Electric resistivity of sheet Interface resistivity

between inner and outer rolls
0.00005 [Ω-mm² ]
Thermal Properties
Heat conductivity of rolls
Env. Temp = 20 C
Convection = 0.02 N/mm/S/C
Heat conductivity of rolls
Heat conductivity of sheet (Ti-64) Interface heat transfer coef.

between outer roll and sheet
41.86 [N/S/C/mm]
Interface heat transfer coef.

between inner and outer roll
Heat capacity of sheet (Ti-4.4Al-3Mo) 62.79 [N/S/C/mm]

Strain Rate Distribution
- Slow rolling speed (0.025 RPM) produced a very low strain-rate (~ 0.023 Max.)
- Strain rate is the highest (~0.023) at the entry and it gradually decreases
towards the exit (~0.003)
0.023 0.003
Electric Voltage Distribution
- Voltage drop in top inner roll: - Voltage drop in top outer roll: - Voltage drop in all objects
0.6 -> 0.479 [V] 0.479 -> 0.440 [V]
0.480 [V]
0.432 [V]
- Voltage drop in sheet: 0.458->0.147 (center) [V]
Top edge
0.458 ~ 0.449 [V]
Electric current is supplied through the center of top inner roll

Since contact area between outer roll and the sheet is small,
Top center the current intensity is high and so is the heat generation
0.436 ~ 0.417[V] (~ a high voltage drop is expected)
Temperature Distribution
- Voltage drop in all objects
T = 10 s
T = 20 s
The core of sheet was heated rapidly in the beginning and then gradually later on
T = 50 s
T = 100 s
T = 250 s
The core temperature stays about at 1050 C

The surface of the sheet lost heat to the roll, and it becomes cooled to 895 C
Temperature Distribution in Roll Bite
Time = 0 s Time = 50 s
edge
center

Effect of Voltage on Heating
Temperature-time curve
1200
Forming temp. = 950 C ~1100 C at 0.6 [Volts]
Point 1 (0.6V)
1100
Point 2 (0.6V)
Point 3 (0.6V)
Temperature(C)
1000
Point 4 (0.6V)
Point 1 (0.5V)
900
Point 2 (0.5V)
Point 3 (0.5V)
800
Point 4 (0.5V)
700
600
0 100 200 300 400 500
Time(sec) Temperature varies about 120C (center) and
Reaches the ideal forming temp: 150 s
30C (edge) through thickness
Roll speed: 0.025 RPM
center edge
Comparison of Voltage Drop
Voltage-time curve
0.5
Point 1 (0.6V)
0.4 Point 2 (0.6V)
Point 3 (0.6V)
Voltage(V)
Point 4 (0.6V)
0.3
Point 1 (0.5V)
Point 2 (0.5V)
0.2 Point 3 (0.5V)
Point 4 (0.5V)
0.1
0
0 100 200 300 400 500
Time(sec)
For both the applied voltages of 0.6[V] and 0.5[V],

voltage drops are 0.2[V] at the center and 0.04 [V] at the edge
center edge
Resistance Heating Module Validation:
Effect of “Interface Resistivity + Voltage”
Case A: ρinterface = 50.0 [Ω-mm²], V=600 (volts) Case B: ρinterface = 0.0005 [Ω-mm²], V=0.6 (volts)
ρ = 0.00025 [Ω-mm]
Potentials: ρ = 0.00025 [Ω-mm] Potentials:
599.98 (v) 0.48 (v)
299.35 0.432
299.34 0.357
ρ = 0.002 [Ω-mm] 299.32 ρ = 0.002 [Ω-mm] 0.299
299.31 0.242
299.98 0.167
0.019 (v) 0.119 (v)
ρ = 0.00025 [Ω-mm]
ρ = 0.00025 [Ω-mm]
Majority of electric potential drops are at two contact zones ! Electric potential drops is gradual and more in the Ti-sheet
Case A: Temperature rise is driven by interface resistivity Case B: Temperature rise is driven by resistivity of Ti-sheet
Note: Initial temperatures of all the objects are 23C.

Resistance Heating Module Validation:
V2
Power = P = VI = = I 2R
R
Case A: Temperature rise is driven by interface resistivity Case B: Temperature rise is driven by resistivity of Ti-sheet
Heat is generated at the sheet/roll interface

Heat is generated from the center of workpiece
and is propagating to other areas..
Case Study 2
Continuous Electric Resistance Heating:

Hot forming system for high alloy metals with poor workability
Journal of Materials Processing Technology 209 (2009) 3060~3068
By Jun Yanagimoto, R. Izumi

Rapid Forming System with
Continuous Electric Resistance Heating
- Forming of high-alloy metal sheets and bars with precise and flexible control
- Better formability at elevated temperatures (only in a narrow temperature range)
- Precise and stable control of temperature is essential
J. Yanagimoto (2009)
Prototype Forming Machine
- Prototype forming machine proposed by J. Yanagimoto (2009)
- Capable of the high speed forming of metals with precise & flexible temperature control
- Two basic components : electric resistance heating + rapid forming system
~ a rolling mill located next to the heating system
Schematics of
Electrodes & Electric Circuit
- Rapid rise to the uniform delivery temperature

- High alloy metals running between
two rotating disk electrodes
- Metal temperature is raised by resistance heating
FE Modeling of
Heating and Forming
Electric resistance at interface
between roll and sheet: 0.0005 Ω-mm Electric resistivity of sheet ρ [Ω ⋅ mm]
(2nd operation)
Applied voltage: 2V~6V + ALE Strip Rolling
Electric Resistance Heating

(1st operation) Difficult to form
Ti-Al alloy sheet
The strip is heated by electric resistance

and then formed in rolling mill
Table Enhancements
Flat Table Geometry
- Strip dimensions in simulation
Two contact nodes

at the electrode roll/strip interface
to guarantee an electric current flow.
+ -
Electrodes
Material: Ti-Al alloy
Electric current
Voltage Distribution
Time = 0 s
Time = 2 s
Electric current flow

Predicted Temperatures
- Predicted temperatures (Heating time = 10 sec)
Time = 2 s Time = 4 s Time = 6 s
Very uniform heating

In the rolling dir. !
Temperature Variation
in Strip Thickness
- After 10 sec. resistance heating
Symmetry plane
(center)
Max. difference = 45 C
Edge
Symmetry plane
Edge
(center)
The Rate of Temperature Increase
- Temperature rise is proportional to the duration of current flow though metal
dT R 2 I V Current flux/density J [ A / mm 2 ]
= J J= = [ A / mm 2 ] where
dt Cρ d a Ra I is the electric current (measured in amperes, A)
a is the area (measured in square meter, mm²).
R is the resistance
ρd is the specific heat
C is the density
dT R V 
2
dT V 2
=   ∝
dt Cρ d  Ra  dt R
- Temperature rise is proportional to the square potential difference (voltage)

- Temperature rise is inversely proportional to the resistance
L "ρ" is the resistivity [Ω-mm]

R=ρ
a ( ~ analogous to "R" of Ohm's law which has units of ohms).
Effect of Resistivity
on Temperature Rate
dT
(V=6 volts) Increasing temperature rate.
Temperatuce(C)
dt
2000
R=0.001 Electric resistivity
1800 ρ=0.001
R=0.002
ρ=0.002 [Ω ⋅ mm]
1600
R=0.003
ρ=0.003
1400
1200
1000 Target temp. = 1000 C
800
600
400
200
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Time(s)
Time to target temp: 7.5s 10.3s 15s

Estimated running speed: 30 mm/s 22 mm/s 15 mm/s
L distance between electrodes

Heating time t=
V running speed
Effect of Voltage
on Temperature Rate
dT
(R=0.002 Ohm-mm) Increasing temperature rate.
Temperatuce(C) dt
1400
2V
3V
1200
4V
5V
1000
6V
800 7V
600
400
200
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Time(s)
Temperature profile changes (between 4~10s) for various voltages

can be used to determine processing window.
Effect of Voltage
on Temperature Rate
dT V 2 Temperature rise rate ~ 1. proportional to the square voltage

∝
dt R 2. inversely proportional to the resistance
Temperature increase rate-voltage curve

Temperature increase rate-resistivity curve
120
y = 1.5564x2 + 5.113x - 1.1983 140
Temperature increase rate (C/s)
Temperature increase rate(C/s)

100 y = 0.102x + 33
120
80
100
60
80
40
20 60
ρ=0.002 [Ω ⋅ mm] V = 6 [Volt]

0 40
0 2 4 6 8 0 200 400 600 800 1000 1200
Voltage (Volts) 1/Resistivity [1/Ohm.mm]
Temperature in Rolling
(2nd operation)
ALE Strip Rolling
Top roll 20 C < 800 C
50 C
> 995 C
Bottom roll 800 C < T < 995 C

Temperature Variation
in Strip Thickness
Temperature-time curve Center
- After resistance heating
1000 Point 1 T=990
Point 2
980 Point 3
Center Edge
Temperature(C)
Point 4
960
940 Edge
920 T=960
900
880
4 locations for tracking… 9 9.5 10
Time(s)
- Before rolling 1000
Point 1
900
Point 2
800
Point 3
700
Point 4
Temperature(C)
600
500
- After rolling
400
300
200
100
0
0 2 4 6 8 10
Time(s)
Strain & Strain Rate Distributions
ε = 0.05 ~ 0.42
ε& = 1.02 ~ 8.18

Future Work
♦ Interface Resistivity will be a function of both contact temperature

and pressure.
♦ Verification and Validation

Roll Flattening
4-High Roll Simulation
Original model by K. P. Kang at Solution Lab.

Flat Rolling Process
- A single stand, four high set of rolls - Roll stack deformation model
Primer on flat rolling (John G. Lenard) (Liu et al 2007, Iron and steel Technology 4(8): 70-80)
- Roll torques and the roll separating forces acts on the journals of the back-up roll bearings,
keeping the center-to-center distance of the bearings as constant as possible
- The energy requirement can be decreased as small diameter work rolls are used.
- However, reduced strength of the work roll and this requires the use of massive back-up rolls to
minimize the deflections of the work roll
FE Model and Movement BCC
- Finite element model: Upper right (1/4) model for ALE simulation
Back-up roll (Elastic) E= v= 1600 mm

Workpiece Elastoplastic Work roll (Elastic) 200GPa 0.3 800 mm
Initial thickness 25 mm
Final thickness 15 mm
Width 600 mm Elements: 11655
Stationary back-up roll
Fixed nodes
Elements: 11900
Work roll movement BCC
Elements: 3600 Ω = 2 [rad/sec]
Fz = 600 KN
DEF_ALE.DAT
No updating of the work roll coordinates from rotation
FE Mesh and Effective Stress
(Full model is constructed by mirroring)
- Four high roll setup for roll flattening study
Predicted effective stress

Strain and Stress Distribution
Von Mises Strain Distribution
- Elastic strain distribution in the work roll and back-up roll

Z-Stress Distribution
- Z-stress in the work roll and back-up roll are due to elastic deformation
Z-Displacement Distribution
- Z-displacement in the work roll and back-up roll are due to elastic deformation
State Variable Variation
in Strip Width
Z-stress (MPa)
A B
A B A B
Convergence of Normal Pressure
during ALE Simulation
Step no. 100 Step no. 200
A B A B
Step no. 250 Step no. 300 Step no. 1000
Steady-state
A B A B A B
State Variable Variation
in the Work Roll
Roll bending predicted

(magnification: x100)
A B
A B A B A B
Comparison of Roll Bending
based on BCC definition
Case A: Case B:
600 KN z-force applied in work roll No z-force applied in work roll
Roll bending predicted
(magnification: x100)
Uniformly Non-uniformly
distributed distributed
600 KN 600 KN V=0
Max. compressive = -651 MPa Max. compressive = -756 MPa
Force control Velocity control

Shape Rolling
Improvements
Shape Rolling Improvements
Overview of Recent Improvements in Shape Rolling Template

- Workpiece rotation between stands (support for a non-quarter model) (v10.1.2)
- Option to import 3-D object into the template (v10.1.2)
- Option to specify a sliding die movement to roll object (v10.1.2)
- Option to control a finer mesh region for a multi-stand rolling (v10.1.2)
- Option to control a finer roll geometry region (v10.1.2) Introduced in v10.1.2
- Enhancements in table setup (v10.2)

- Advanced entry mesh option for ALE rolling (v10.2+)
- Option to control a finer roll mesh region (…in progress for v10.2+)
- Option to specify a front/back tension (…in progress for v10.2+)
- Extended workpiece rotation between stands (…in progress for v10.2+)
- 4-High Roll Setup (future work)
FEM Improvements for
Rolling simulation
- Improved ALE convergence criteria (v10.1.2)
- Improved contact handling (i.e. separation from pusher, contact to table) (v10.1.2)
- Option to turn on/off roll mesh update in ALE run (DEF_ALE.dat) (v10.2)
Applications of Shape Rolling
Template in Industry
- Strip/Plate/Sheet Rolling
~ strip cross-section becoming very thin towards the final pass
- 4-high roll setup (i.e., work roll and back-up roll)

- Roll mesh refinement, Elastic roll deflection
- Asymmetric Rolling (ASR)

~ a higher cross-section area reduction towards the final pass (ex. rail products)
- Extended table setup ~ for a workpiece handling before/after roll stand

- More options to rotate workpiece between stands
- Roll Forming
~ a forming of round tube or channel
- User-defined exit cross section for initial workpiece 3-D ALE mesh
- Advanced entry mesh option for ALE run
Enhancements in Table Setup
Improvements in table setup:

- Extended table definition to create guide shape
- Improved automatic positioning of back and front (flat) table and guide
- Workpiece ALE mesh generation considering a position of back table/guide
Flat table for strip rolling

Guide for asymmetric shape rolling
Guide property parameters: Guide property parameters: Guide property parameters:

Example of guide shapes: - Origin point (X,Y) = (-40,-30)
- Width (W) = 80
- Origin point (X,Y) = (-30,-30) - Origin point (X,Y) = (-40,-30)
- Width (W) = 60 - Width (W) = 60
- Height (H) = 60 - Height (H) = 60 - Height (H) = 80
- Thickness (T) = 5 - Thickness (T) = 5 - Thickness (T) = 5
- Corner radius (Ri) = 5 - Corner radius (Ri) = 30 - Corner radius (Ri) = 30,5,5,40
Square type Round type Arbitrary type

Geometry Primitive for Table/Guide
(available in v10.2)
Option for guide setup
Table Guide
Disabled for table setup
Table positioning data
- All the table property data are stored in the shape rolling template wizard file ShapeRoll.RWZ
ShapeRoll.RWZ
Back Guide & Front Table
Flat top roll
View from
the exit
Back guide
Front table
Front table
Created back guide
(aligned to top of bottom roll)
(aligned to top of the bottom roll)
(No positioning by path line) (positioned by path line)
Flat bottom roll

Asymmetric Shape Rolling
R = 550 mm
2-D Guide shape
Exit Entry
R = 600 mm
R = 30
R = 100
R = 150
R = 30
Workpiece
Different size of contact zones
L = 180 mm
L = 217 mm
Example of Guide Setup in
Asymmetric Rolling
Summary
- Use front and back guides
- Position them appropriately
- Apply velocity constraints perpendicular to rolling direction on the entry if necessary
Front guide
generated & positioned Rolling dir. (X-dir)
Fixed velocity BC (Y,Z)
if necessary
Back guide generated & positioned

Enhanced GUI for
Rotation Axis and Center
Top roll in stand #1 (X=0)
Enhanced GUI behavior
updated when 2D roll

geometry is created
Top roll in stand #2 (X=0)
Stand #1
(X=0)
Stand #2 Updated when 3D
(X=60) roll geometry is created
Entry Mesh for ALE Rolling
- Selection of entry cross-section from previous operation
(n)th operation (n+1)th operation
Entry Last roll contact Exit Entry
Transfer 2-D mesh and state variables
Two locations selectable in SRT GUI:

1. Cross section at Exit
2. Cross section at Last roll contact
Advanced Entry Mesh Option
ENTRYMESH.DAT ~ Input file to DEF_SHAPE_ROLL_CTRL3.exe

File format
- option to choose a location of entry mesh
Line #1) OPR NO (integer, n>1)
- option to impose a velocity continuity Line #2) SV EXIT (integer, 0 or 1)
Line #3) X ENTRY (real, 0.0~1.0)
in the rolling direction (x-dir) Line #4) X CONTINUITY (integer, 0 or 1)
(n)th operation
Entry Exit
0.0
(n+1)th operation
1.0
Entry
X ENTRY Entry NEXT
Exit
Last roll contact
Entry NEXT
Selected section
as the next entry
Entry NEXT = Entry + (Exit - Entry) * X ENTRY

Example of X ENTRY in
Advanced Entry Mesh
Line #1) OPR

- Effect of X ENTRY on the entry mesh in the (n+1)th operation Line #2) SV
NO
EXIT
Line #3) X ENTRY
Line #4) X CONTINUITY
ALE workpiece mesh in the (n)th operation Entry CS in the (n+1)th operation
X ENTRY =0.9
X ENTRY =0.5
X ENTRY
0.1 0.5 0.9

X ENTRY =0.1
0.0 1.0
Example of SV EXIT in
Advanced Entry Mesh
ALE workpiece mesh in the (n)th operation Copied state variable into the (n+1)th operation
X ENTRY =0.53
l e copy
b
e varia
Stat
SV EXIT =1
State variables copied from
the exit cs of the last operation
Exit
X ENTRY =0.53
a bl e copy
var i
State
SV EXIT =0
State variables copied from

the section selected as entry
for the (n+1)th operation
Example of X CONTINUITY in
Advanced Entry Mesh
- Continuity of longitudinal velocity (Vx) in strip

is important in roll forming since deformation OPR. #2
takes place between stands as well.
Line #1) OPR NO

Line #2) SV EXIT
Line #3) X ENTRY
Line #4) X CONTINUITY
OPR. #1 X CONTINUITY = 1
Rolling dir. (x-dir)
Need to preserve Vx(FEM) on the exit

of previous operation by imposing
velocity constraints on the entry
Modeling of Roll Forming
by Shape Rolling Template
14 Passes Tube Making Process

ALE simulation conducted by T.Y Lee at Solution Lab.
Behavior of Metal Strip
in Roll Forming
- A long strip of metal (typically coiled steel) is passed through consecutive sets of rolls,
or stands, each performing an incremental part of the bend in the transversal direction,
until the cross-section profile is gradually transformed into the required shape.
- Forming occurs not only at the contact between tool and metal strip,
but also in the region between roll stands.
Roll stand 1
Roll stand 2
Redundant Deformation
in Roll Forming
G.T. Halmos, Roll Forming Handbook
- Redundant deformation:
1. Longitudinal elongation / shrinkage

~ the most critical in tube making process
2. Longitudinal bending and bending back
3. Transversal elongation / shrinkage
- Redundant deformations are superimposed on the transversal bending.

- They greatly influence on strain, stress, springback after forming,
and residual stress in final product.
Longitudinal Elongation
- Deformation along strip edge ?
• Strip edge portion usually moves G.T. Halmos, Roll Forming Handbook
along flow line which is longer than
that of center portion.
• The center part travels straight line,

while the edge portion often rise vertically
and shift horizontally
toward the center of the cross-section
• In manufacturing of ERW tube,

if a local edge elongation becomes excessive,
it is difficult for the elongated edge portion
to shrink smoothly. (~ edge wave may occur…)
Flower Diagram for
ERW Tubes
#9 #10 Allocation of the increment of
#11 #12 #13
#14 profile angles for minimizing
#6 #7 #8 edge stretching
#5
#4
#3
t 2.77 X D 61.0
D.H. = 0
#2
Pass-Line:
Bottom Line: Horizontal
#1
Initial strip
Design criteria: 1. Minimization of edge stretch

(by making the maximum longitudinal strain, that occurs at the edge portion
during every interstand, equal to each other)
2. Equalization of driving roll torque
(the power of deformation dissipated in metal strip at each interstand
deformation are made equal to each other)
Roll Profiles for
ERW Tubes
Breakdown roll Cluster roll
#1 #2 #3
#4 #5 #6
Fin pass roll
#7 #8 #9 #10
#11 #12 #13 #14

FE Modeling of Roll Forming
Dimensions: Initial strip (184.15w X 2.77t), Final tube (2.77t X 61.0d)

Forming stands: total 14 roll stands
Roll Type: driving roll (top & bottom roll), idler (side roll)
Forming speed: approx. 700 mm/sec
Workpiece object type: rigid-plastic or elasto-plastic
FE Model: half model (with a symmetry condition)
Simulation Model: “1-Stand” or “2-Stand” ALE simulation
Advanced ALE 3-D mesh: user-defined exit cross-section (with mapping points)
Advanced ALE 2-D entry mesh option
Simulation Setup for 1st Roll Stand
Rolling dir.
ALE initial mesh shape
Exit Entry
ALE Mesh with
User-Defined Exit Cross-section
- Location of Mapping Points (1,2,3,4) for 1st Roll Stand
2 Entry
3
Entry
1 4
by n
User-defined exit h ing latio
es rpo
M te
In
r.
di
g
l lin
Ro
Exit
Deformed Strip at Each Stand
(Stand no. 1 ~ 6)
Effective strain
#1 #3 #5
#2 #4 #6
Deformed Strip at Each Stand
(Stand no. 7 ~ 14)
Effective strain
#7
#9 #13
#11
#8 #10 #14
#12
Deformed Strip
Cross-Section at Roll Exit
Initial strip Longitudinal Strain
(x-strain)
Large strain
increments!
#1 #2
#4 #5
#3
Large strain
increments!
#6 #7 #8 #9 #10
#11 #12 #13 #14

Longitudinal Strain Distribution
Edge ~ Elongation (tensile)

- Mechanism of occurrence of longitudinal
elongation and shrinkage metal strip ε xx = 0.057
Edge
Intermediate
Roll Stand no. 14 ~ Shrinkage

(compressive)
Center ε xx = −0.0063
Intermediate
Center ~ Elongation (tensile)

ε xx = 0.0059
Longitudinal Strain History
Roll Stand no. 14

Longitudinal Strain vs Stand no.
0.07 Edge
Relative long flow line (elongation)
0.06 Edge
Intermediate
0.05
Center
Longitudinal Strain
0.04
Intermediate
0.03
0.02
Relatively short flow line (~a little elongation)
0.01
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
-0.01
Center
Stand no.
P5: Edge
P3: Intermediate
P1: Center
Longitudinal Strain Increment
Large longitudinal strain increments! Longitudinal Strain increment at each stand

0.012
0.01 Edge Center
0.008
Longitudinal Strain
0.006
0.004
A little elongation & shrinkage
in the center portion
0.002
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
-0.002
Stand no.
Stand no. 2 Stand no. 6

Large strain
increments!
Large strain
increments!
Convergence of Strip Shape in
Roll Stand No. 6
Initial tube shape for ALE analysis
ALE analysis….in progress
ALE analysis….reached steady-state

Effective Strain & Stress
Distribution
Roll Stand no. 6
Highest strain and

stress values
along the strip edge
due to stretch
Effective Effective
Strain Stress
History of Maximum Effective Strain
Max. Effective strain vs Stand no
0.5
0.4
Max. Effective Strain
0.3
0.2
Roll stands 6, 7, 8
generate
large strains
0.1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Stand No.
#7 #8
#6
Merging of Roll Formed
Tube (½ model) for ERW
e Full FE Model
er g
oring 2 . M
rr
. Mi
1
The two edges to be joined are merged
together in a V of about 4 to 7 degrees.
Full FE model
with state variables
copied
½ FE Model
Model further can be used for heating study

by electrical resistance heating
2-Stand Modeling Approach
2-Stand
Analysis - Use the mid-section between the
stands of 1st operation as the entry
1-Stand for the next operation
Analysis
Entry NEXT = Entry + (Exit - Entry) * X ENTRY
Te
ns
OPR #1
io n
`
1+2
ENTRYMESH.DAT
#1 Entry NEXT Line #1) 2 OPR NO
Line #2) 0 SV EXIT
Line #3) 0.5 X ENTRY
Line #4) 1 X CONTINUITY
Te
2+3
ns
io n
#2
OPR #2
#3
Advance Entry Mesh Option in
2-Stand Modeling
- Tension may exist between two stands ENTRYMESH.DAT
Te
due to difference in roll rotation speed
ns
ion
Line #1) 2 OPR NO
`
Line #2) 0 SV EXIT
- The effect of tension can be considered
Line #3) 0.5 X ENTRY
(SV EXIT =0 , X ENTRY =0.5)
Line #4) 1 X CONTINUITY
Rolling dir.
- Velocity continuity also can be kept
(X CONTINUITY =1)
OPR 2 OPR 4
New Multiple Operations: OPR #1 OPR #2 OPR #3 OPR #4 OPR #5 …
OPR 1 OPR 3
Te
Te
ns
ns
ion
ion
`
`
2-Stand ALE Simulation
- Roll rotation speed
9.917 rad/s ALE analysis….in progress

9.31 rad/s
18.46 rad/s
13.5 rad/s
- Effective strain
ALE analysis….reached steady-state

Summary of
QA activities in DEFORM
DEFORM System Testing
Outline of the presentation.

• Scope of GUI and system component testing
• Summary of labs and release examples used in testing
• Internal FEM test examples
• Basic components and scope of FEM auto testing procedures
• Typical input and output of auto testing scripts
• Summary of the old auto test examples (prior to 2006)
• Summary of new auto test examples currently being developed
• Spec documents and test guidelines
• Summary
DEFORM PRODUCT TESTING DOMAIN FOR GUI
2D F2 3D F3 2D3D F23
Pre Pre Pre Pre Pre Pre

Post Post Post Post Post Post
GUI Main Simulate GUI Main Simulate GUI Main Simulate
Templates Templates Templates
Tools Tools Tools
Simulator Simulator Simulator
DEFORM 2D TESTING DOMAIN FOR GUI
GUI Main Pre Simulator Tool Post Stand alone
2DPre Run Options Inv HT 2D Post Die Stress

Machining Batch queue Preform Microstructure Distortion
Forming Process Opt. 2D/3D MO2
Die Stress Monitor Post Machining
Distortion Simulation
HT Graphics
MO2
DEFORM 3D TESTING DOMAIN FOR GUI
GUI Main Pre Simulator Tool Post Stand alone
2DPre Run Options Inv HT 2D Post Die Stress

Machining Batch queue Preform Microstructure Distortion
Forming Process Design. MO3
Die Stress Monitor Machining
Cogging Simulation
HT Graphics
MO3
Shape Roll
Ring Roll
OTHER SYSTEM COMPONENTS
Passwords Installation Services Drivers License setup Documentation
OPERATING SYSTEMS
HP-UX11.00 Centos4 Suse 9.2 Win 7
HP-UX 11.23 Redhat4 Suse 11.0 VISTA
Centos5 Win XP
2D Labs:
DEFORM-2D_Cutting_Lab -1
DEFORM-2D_Diestress_Lab -2
DEFORM-2D_Heating_Lab -1
DEFORM-2D_HT_Labs -8
DEFORM-2D_Inv_Heat_Trans_Labs -2
DEFORM-2D_Labs - 25
DEFORM-2D_Machining_Distortion_Lab -1
DEFORM-2D_Multiple_Operatons_Lab -2
DEFORM-2D_Preform_Opt_Labs -2
DEFORM-2D_Resistance_heating_lab -1
DEFORM-2D_Tool_Wear_Lab -1
DFEORM-F2_Labs -1
TOTAL - 47
3D Labs:
DEFORM-3D_Cogging -1
DEFORM-3D_Diestress_and_Wear -3
DEFORM-3D_HeatTreat_Wizard -1
DEFORM-3D_Inverse_Heat_Transfer -1
DEFORM-3D_Labs - 13
DEFORM-3D_Machining -3
DEFORM-3D_Microstructure -1
DEFORM-3D_Multiple_Operations -1
DEFORM-3D_Preform -1
DEFORM-3D_RingRolling -4
DEFORM-3D_ShapeRolling -2
DEFORM-F3_Labs -3
TOTAL - 34
2D DATA folder release examples:

Creep -2 Multiple Deforming Objects -3
Die Stress -3 Multiple Hammer Operations -1
Elasto-Plastic -2 Multiple Operations -3
Extrusion -5 NAFEM benchmarks -4
Floating Objects -2 Plane Stress -3
Forging -6 Porous Objects -1
Fracture -2 Press Modeling -4
Gravity Loading -4 Radiation -1
Heat Treat -4 Resistance Heating -2
Induction Hardening -1 Resistance Spot Welding -4
Induction Heating -3 Rolling -3
Inertia Welding -1 Sheet Forming -1
Machining -3 Shrink Fit -2
Multipass Rolling -1 Tool Wear -1
Sintering_2D -3 View Factor -5
TOTAL - 79
Run time ~ 2 days /OS

Repeat on all supported systems
3D DATA folder release examples:

Cogging -1 Multiple Operations -1
Die Stress -3 NAFEMS benchmarks -3
Extrusion -1 Rolling -8
Floating Objects -1 Sheet Forming -1
Forging - 22 Special Applications -2
Fracture -2 Thread Rolling -1
Heat Treatment -2 Tool Wear -2
Induction Heating -3 View Factor -4
Induction Hardening -1 Sintering_3D -3
Metal Cutting -2
TOTAL - 63
Run time ~ 8 days

Repeat on few supported systems, 32 bit and 64 bit mode
running in MPI and non MPI mode. (2-4 weeks, 3-4 PCs)
3D and 2D internal test cases for FEM procedure checks

(most of these from users):
Forging (3D) - 61 General Forging (2D) - 28
US,UK, Korea, Japan (several users)
Germany,
Internal Benchmarks
Cogging(3D) -8
Industry
Benchmarks
Shape Rolling (3D) -4
Ring Rolling (3D) -5
Industry
Benchmarks
TOTAL - 106
Run time ~ 20 days

Repeat on few supported systems, 32 bit and 64 bit mode
running in MPI and non MPI mode. (4-7 weeks, 4-6 PCs)
Basic procedures and variables used in Auto testing scripts (CVS module ‘auto_test’)
For checking FEM2D: Auto_test2.exe

For checking FEM3D: Auto_test3.exe
Input: Basic keyword files, reference values to compare fem results (*.TEST)
Output: Results from current version and % deviation and pass/fail flag (*.TEST.OUT)
(this is a also test for text based Pre, keyword reading, DB writing, and DEF_ARM
procedures in text mode)
Typical test variables checked at any given node/element including min/max for an object
(list includes current functionality, can be checked at a specified step or at the last step in DB)
Nodal coordinates Elemental stress (including component values)

Nodal displacements Elemental strain (including all the components)
Nodal velocity Phase volume fractions (including Grain, Hardness data)
Nodal strain Atom data, Current, Voltage
Nodal stress Wear, Die load, Pressure, Energy, Volume
Nodal damage Number of nods, Number of elements
Nodal temperature User variables (nodal and elemental)
Basic execution flow of Auto test procedures

xxx.TEST
RUNSIM PID
Auto_test module DBREAD
RZ …..
………….
PID.KEY ………
Text Pre
DB
DEF_ARM
DEF_SIM
REMESH
xxx.TEST.OUT
Database PID.DB, Step ….
Extract results RZ ……………………Pass
………….
………
2D basic FEM Test cases: (designed prior to 2005)
2d_basic deformation models - 68

Elastic models -5
Grain models -7
Heat_Treat basics - 66
Press_Modeling -9
Spring_Loaded_dies - 13
2d_basic thermal examples - 92
View_factor examples -8
TOTAL - 258
Run time ~ Overnight

3D basic FEM Test cases: (designed prior to 2006)
2d3d (equivalent cases in 2d and 3d) - 122

3D_basic deformation, thermal and heat treat - 193
Anisotropy models -6
Compression models -2
Mixed_elasto-plastic models -2
Movement_Control models - 11
Sliding_die examples -9
Stopping_control examples - 10
Strain component examples - 12
View_factor examples -7
TOTAL - 404
Run time ~ 1 day

Typical input and output to Auto test procedures … basis for most cases
being engineering judgment and working solution from earlier versions ..
2d_basics\new\2D_FEM_cases\Stage1\Step_controls
Input data
Output data
Typical input and output to Auto test procedures … basis for most cases
being engineering judgment and working solution from earlier versions ..
2d_basics\new\2D_FEM_cases\Stage1\Process_conditions\Heat_Transfer
Input data
Output data
Nomenclature used for auto test example input keyword files

Additional FEM Test Cases on 2D simulation controls for detailed testing:
FEM2D Axi-symmetric test cases:
Step Controls:
Die Displacement - 188
Time Increment - 144
Stopping Controls - 129
Remesh Criteria - 12
Iteration - 49
Process Conditions:
Heat transfer - 48
Diffusion - 176
Induction -4
Constants - 62
Advanced:
Output control - 32 Total - 734
FEM2D Plane Strain test cases:
Step controls:
Die displacement - 188
Time increment - 171
Stopping controls - 182
Remesh criteria - 12
Iteration controls - 49
Process conditions:
Heat transfer - 48
Diffusion - 176
Constants - 62
Advanced options:
Run time ~ 1 day

FEM2D Plane Stress test cases:
Step controls:
Remesh criteria -8
Process conditions:
Heat transfer - 48
Diffusion - 176
Constants - 56
Advanced options:

FEM2D Torsion test cases:
Step Controls:
Die Displacement - 24
Time Increment - 24
Remesh criteria -8
Advanced:
Output control - 22
Total - 151

Additional 3D Simulation controls FEM Test Cases (Tet Mesh) :

Step Controls:
Process Conditions:
Heat transfer - 44
Diffusion - 176
Induction -4
Constants - 95
Advanced:
Output control - 24
Control Files - 12 Total - 960
Run time ~ 1 day

Additional 3D Simulation controls FEM Test Cases (Brick Mesh) * :

* Currently working on
Step Controls:
Process Conditions:
Heat transfer - 44
Diffusion - 192
Induction -4
Constants - 95
Advanced:
Output control - 24
Control Files - 12 Total - 932
Run time ~ 1 day

Testing Documentation Methodology:

Spec Documents for:
These documents are prepared in detail indicating the entire GUI
map with its fields and their function. This documents gets
modified as and when new pack gets released. As of now spec
documents are available for:
DEFORM 3D Pre
DEFORM 3D Post
F2 & F3
Excel Sheets:
These excel sheets are used for various purposes of identifying
the combinations to be used follow up of bugs and reporting the
bugs.
Bugzilla
Combination Sheet
LM Testing
Test Report
FEM Test cases
Details on FEM test case generation
Sample of FEM Test case sheet for the preparing FEM Test cases. It
consists of the complete setup details of the test case and its
objective. Keyword name follows a defined nomenclature
• Continued effort in FEM testing procedures

• Continued effort to document FEM test examples
• Continue developing analytical solutions for verification and
validation of simulation results wherever possible
• Explore auto-testing GUI tool to improve efficiency and maintain
release schedules
Supported OS and
Release Plans
Supported OS and Release Plans
Supported OS Kernel Kernel

(DEFORM v10.1) (DEFORM v10.2)
Centos 4.7 2.6.9-89 2.6.9.100
HPXC 2.6.9-42 2.6.9-42
Suse92 2.6.8-24 (limited support)*
Redhat 2.8 2.4.20-28 (no support)
HP-UX 11.11 (limited support)*
HP-UX 11.23 (limited support)*
Suse Enterprise Linux Desktop No support 2.6.32-29 (Suse 11)
Centos 5.6 No support 2.6.18-238
Supported PC Supporting (DEFORM v10.2)

PC 32 bit XP(**), Vista(**), Win7
PC 64 bit Win7, Vista(**)
* Limited support means, new functions/modules can not be built/supplied due to the incompatibility of
the system building tools on the consolidated platform/OS.
** Microsoft has decided to stop the support of XP in 2009 and Vista in 2012.
Supported Unix/Linux OS Fortran Compiler (user routine support)

DEFORM v10.1 DEFORM v10.2
Centos 4.7 Absoft f90 v10.0 (64 bit) Absoft f90 v10.0 (64 bit)
HPXC Absoft f90 v10.0 (64 bit) Absoft f90 v10.0 (64 bit)
Suse92 Absoft f90 v9.0 (32 bit) Limited support *
HP-UX 11.11 HP Fortran Limited support *
HP-UX 11.23 HP Fortran Limited support *
Suse Enterprise Linux Desktop No support Absoft f90 v11.0 (64 bit)
Centos 5.6 No support Absoft f90 v11.0 (64 bit)
Supported PC Fortran Compiler

Absoft f90 v7.0 (32 bit) Discontinued
Absoft f90 v9.0 (32 bit) Absoft f90 v9.0 (User routine support available)
Absoft f90 v11.0 (64 bit, full support) **
* Limited support means, new functions/modules can not be built/supplied due to the incompatibility
of the system building tools on the consolidated platform/OS.
** System builds are from Absoft f90 v11.0
Supported Unix/Linux OS MPich

Centos 4.7 v1.2.1(32 & 64 bit) v1.2.1(32 & 64 bit)
HPXC v1.2.1(32 bit) v1.2.1(32 bit)
Suse92 v1.2.1(32 bit) v1.2.1(32 bit)
HP-UX 11.11 v1.2.1(32 bit) v1.2.1(32 bit)
HP-UX 11.23 v1.2.1(32 bit) v1.2.1(32 bit)
Suse Enterprise Linux Desktop no support v1.2.1 (32 & 64 bit)
Centos 5.6 no support v1.2.1 (32 & 64 bit)
Supported PC MPich
XP, Vista,Win7 v1.2.1(32 bit) v1.2.1(32 bit)
Vista, Win7 v2.1.2(64 bit) v2.1.2(64 bit)
♦ DEFORM v10.2(beta1) released for distributors on 4/11/2011

includes
• DEFORM 2D v10.2
• DEFORM 3D v10.2
• F2 v10.2
• F3 v10.2
• Integrated 2D3D v10.2
• Integrated F23 v10.2
• DEFORM v11.0(beta) (only integrated system and new modules)
♦ DEFORM v10.2(beta2) is scheduled for 5/15/2011

(Schedule subjected to internal testing and only for PC)
Compatibility Chart
for
License Manager, Product and Password versions
Compatibility Chart
License Manager version – Product version

Which version of License Manager is needed to run which version of the product ?
2D v7.2 2D v8.0 2D v8.1 2D v8.2 2D v8.3 2D v9.0 2D v9.1 2D v10.0 2D v10.1 2D v10.2 2D v11.0b
LM 2.0
x x x x x x x
LM 2.1
x x x x
LM 3.0
x x x
LM 3.0.1
x x
LM 3.0.2

LM 3.0.3

Compatibility Chart
License Manager version – Product version in the password

Which version of the License Manager can understand which product version in the
password ?
LM 2.0
x x x x x x x
LM 2.1
x x x x
LM 3.0
x x x x x x x x x x
LM 3.0.1
x x x x x x x x x
LM 3.0.2
x x x x x x x
LM 3.0.3
x x x x x x x
Note: (DEFORM v11.0 beta can be run using DEFORM v10.2 password and LM v3.0.2 or higher)
Design Environment for FORMing
DEFORM Installation Procedure

DEFORM Installation Procedure
♦ PC
♦ Linux
DEFORM Installation - PC
Sentinel hardware key driver

• Remove hardware key prior to installation.
• Install with administrative privileges.
• Set time and date correctly on the computer.
Use password file (deform.pwd) during installation

• The password file is requested during the install.
• License Manager will start automatically if the password is used.
• Correct shortcuts will be generated if the password is used.
• License Manager can be started manually if the password is not used during
installation.
• Shortcuts can be changed using Start menu “Configure DEFORM Shortcuts”.
Configuring MPICH2 for the 64bit simulation engine

• Install MPICH2 if you have a 64bit Windows OS.
• DEFORM User Area contains “64_Bit_configuration.pdf”:
– Open a command prompt as administrator. On XP – log in as administrator. On Vista and
Windows7 - start the command prompt “as administrator”.
– Change to the MPICH2 directory: “cd c:\program files\mpich2\bin”.
– Type “smpd.exe –install”.
– Type “smpd.exe –restart”.
– Type “mpiexec.exe –register”.
– Provide a login and password for a valid user account. DEFORM will run under this user
account. If the account is stored on a domain, enter the username with the format
“domain\username”.
• If the login password for that user account changes, it is necessary to run
“mpiexec.exe –register” again.
Configuring Batch Queue to run with the 64bit FEM engine (1 of 3)
Go to Services, right-click on “BatchQueueServer” and select “Properties”.

Select “Log On” --> “Browse…”, enter the user account name -->“Check Names” to
locate the account. If the user account is on a domain, choose “Locations…” to
change the target location. Click OK, enter and confirm the password.
Restart the BatchQueueServer by right-clicking --> “Restart”.
Repeat this procedure for the SimulationServer service.

The empty file '64bit.DAT' is required in the problem folder to run the
64-bit engine. Without this file, the regular 32-bit FEM code will run.
Starting in v10.2, this can be set in Run (Options).
Programs to allow through the Windows Firewall

• Smpd.exe
• Batch Queue server
• Simulation server
• License Manager server
Configuring DEFORM Setup

DEFORM Setup – Server machine

• License Manager points to this server machine.
• Batch Queue points to this server machine (typically).
• Simulation servers set for all the machines that may run simulations.
Only needed when Batch Queue is used.
Only needed when Batch Queue is used.

DEFORM Setup – Server machine
Once the License Server, Batch Queue and Simulation Server information is set,
click on “Save Locally and Commit to Server”.
DEFORM Setup – Client machine

• Set to “On Remote License Server” and specify server name.
• Click “Check Server”.
• Click “Get Configuration”.
• Click “Save All Changes Locally”.
“Get Configuration” is only

1 2
needed when Batch Queue
is used.
3
DEFORM Setup – Client machine

• Changes can be made to the Simulation Server list from the Client machine.
• Click “Get Configuration”.
• Add client computer to the list
of Simulation servers.
• Click “Save Locally and Commit
to Server”.
2
DEFORM Installation - Linux
Sentinel hardware key driver

• Remove hardware key prior to installation.
• Set time and date correctly on the computer.
• Install as root user.
• Using Sentinel driver v7.4+, an additional command is often required after a
reboot (depends on OS). From the installation folder (opt/safenet_sentinel/
common_files/sentinel_usb_daemon), issue this command as root:
./load_daemon.sh support
Installing DEFORM to the default location is preferred

• License Manager and Batch Queue will work properly.
• If non-default location is used, scripts in /etc/init.d have to be manually edited:
echo "start DEFORM Batch Queue Server”

cd /usr/local/SFTC/DEFORM/v10.1 (Batch Queue script)
./BatchQueueServer &
Simulation server must be manually started (for Batch Queue)

• License Manager and Batch Queue are started automatically at reboot and are
owned by “root”.
• The Simulation server must be started by a DEFORM user by going to
usr/local/SFTC/DEFORM/v10.1 and issuing the command:
./SimulationServer &”
Running 64bit simulation engine on Linux

• The DEFORM CentOS installation includes 64 bit support for the FEM engine.
• Binaries are located in the folder /usr/local/SFTC/DEFORM/v10.1/3d/EXE64
• To use the 64 bit FEM engine, back up the DEF_SIM*.EXE files from the /EXE
folder and replace them with the files from the /EXE64 folder.
• Starting in v10.2, no file copying is required and the 32bit/64bit option is
set in Run (Options).
Configuring DEFORM Setup

For the License Server, use the computer name instead of an IP address. Several
customers had difficulty with communication when they used the IP address.
lime
Batch Queue and multiple user accounts (1 of 3)

• Create individual user accounts for each user (user1, user2, etc.).
• Create a generic DEFORM user account to control the Batch Queue (deform).
• Create a DEFORM-specific group (deformgrp).
• Make the deform-specific group the primary group for all of the users, including
the generic DEFORM user account.

• Add “umask 002” to the .cshrc of each user.
• Files in /usr/local/SFTC/LicenseManager can be owned by root.
• Files in /usr/local/SFTC/DEFORM/v10.1 should not be owned by root.
• Run “chmod 666” on the following files to allow read-write access for all users:
/usr/local/SFTC/DEFORM/v10.1/DEFORM_NLM_CONF
/usr/local/SFTC/DEFORM/v10.1/2d/EXE/DEFORM_NLM_CONF
/usr/local/SFTC/DEFORM/v10.1/3d/EXE/DEFORM_NLM_CONF
• Configure DEFORMSetup as root

• Create a new PROBLEM directory for each user in a location that is not a
subdirectory of the user’s home directory.
• This PROBLEM directory should be owned by the user and be associated with
the deform-specific group.
• Run “chmod 770” on this PROBLEM directory to allow read-write-execute by the
owner or members of the group.
• Install deformlmd and deformbqd as services as “root”, allowing the DEFORM
License Manager and Batch Queue to automatically start.
• After a reboot, the Simulation server should be started by the generic DEFORM
user by going to usr/local/SFTC/DEFORM/v10.1 and issuing the command:
./SimulationServer &”
DEFORM aliases
• The aliases used be DEFORM are located in
usr/local/SFTC/DEFORM/v10.1/CONFIG.COM.
• Users should not redefine these aliases using other scripts or procedures
(soft-links for example).
DEFORM v10.1.2 Issues - Linux
Semaphore cleanup
• Semaphores are sometimes not properly cleaned up during simulations. This
has caused simulations to crash.
• The issue has been resolved in v10.2.
Multiple MPI job handling

• When several MPI jobs are running simultaneously, with frequent remeshing, it is
possible for the simulations to crash due to an MPICH-related error.
• The cause has been identified and SFTC is currently testing.
• The issue should be resolved in v10.2.
Batch Queue stability and responsiveness

• Several issues with the Linux Batch Queue have been identified, including long
delays on job submission when licenses are available.
• The issue should be resolved in v10.2.
Thank You
Q&A
Q&A
•Develop multiple blows GUI in conjunction with an F2/F3 format

for increased user timeliness?
•Create a macro / GUI that would create customer pre-production
review packages that are required by our customers?
Q&A
•(2d) Why does the geometry control now add the centerline back
onto the part when using the “check geometry” button and why are
the centerline nodes not held to a “0” point on that centerline? They
float and occasionally cause mesh issues on the ends of the part.
•A change SFTC is making to the software is combining the 2D and

3D under one user interface. I understand that this has been
released as a Beta VERSION, We did not receive that, must have
needed to request it. I would think the new release of V10.2 would
be coming this quarter or 2nd quarter. If this is a significant change
for the user in regards to the interface set-up, I request that this be
covered as a specific topic during the meeting. If it is a minor
change for us (the user), can you either cover it in the Q & A
Session or assign Tom or Mike to review this with us during some
free time.
Q&A
• Advancements in shape rolling template in Deform 3D

• Development of pilger modeling
• Dynamic die geometries to simulate tool wear (roll flattening)
• QC check for different version releases
• DEFORM-3D
• When is it appropriate to use the standard vs. the mixed formulation for EP?
Pilgering
The cold pilgering process relies on The cold pilger mill’s forward motion (left)
four main actions – the tube moves and backward motion (right) rely on the
forward and it rotates while the ring tapered cross section between the dies
dies move back and forth and rotate. and the mandrel to reduce the tube’s
diameter and wall thickness
simultaneously
From “Introducing cold pilger mill technology - An overview of the

equipment and the process” , by Oliver Strehlau
Standard EP 3D
Tetrahedral Element
Properties of Tetrahedral Elements
♦ Volumetric locking is problematic for large plastic deformation in low

order triangular and tetrahedral elements
♦ Remedy methods:
- u-p mixed methods: MINI, Hybrid, Mixed-Enhanced
- Averaging Nodal Pressure (ANP) methods: ANP, F-bar, F-bar
patch
Averaged Nodal Pressure (ANP)
Procedure to get Average Nodal Pressure from stress
1 : Pressure in the element

1
pei = − trace(σ)
p e 3
p e5
Node j
p e2 n
4 3
∑v p i
i
e : Lumped Nodal Pressure
p e p e ⇒p = n
j 1
n (over connected elements)
∑v 1
i
where vi elemental volume
n
p 3
n p1n ∑p i
n : Averaged Nodal Pressure
⇒ pe = i =1
per element
pe n
pn2
Modified internal work for ANP Tet
~int ~ dV ~ = σ − 1( p)
f(e) = ∫ BT σ where σ
V
Displacement/Velocity-Pressure (u-p) Mixed
Tetrahedral element (“Mixed”)
♦ Governing equations
σij, j = 0 in Ω
1
ui,i − p = 0 in Ω
K
♦ Variational formulation
∫δ∆ε(∆σ'+1∆p)dΩ = ∫δu tdΓ

1
∫δ∆p(1: ∆ε − K ∆p)dΩ = 0
Example 1: Large deformation:
Indentation of an elasto-plastic block
♦ Plane strain
- material
1
E = 200GPa
ν = 0.3
1
σ = σ o + Hε p
σ o = 100MPa
H = 1MPa
2
Ref) Neto,Pires,Owen, IJNME,pp353-383 (2005)

Example 1: Large deformation:
Indentation of an elasto-plastic block
2D
(a)Linear Tet(3D) (b) ANP (“Standard”) (c) u-p Mixed (“Mixed”)
3D
Example 2: Small deformation:
Elastic deformation
Fixed BCC (x,y,z)

Material:
E = 16807
ν = 0.311
K = 14821
Note) σ m = Kεv
Applied pressure (=1)
Mean stress (Mesh 1)
Max: - 0.404 Max: - 0.310

Min: -0.606 Min: -0.725
ANP Mixed
Linear
ELASTIC OBJ Max: - 0.304

Min: -0.725
Mean stress (Mesh 2)
ANP Mixed
Linear
Example 3: Small deformation:
Heat treat simulation
♦ Quenching Effective
Stress
1000
Mixed
800 ANP
ANP Mixed
Max. temperature
600 2000
Mixed
400 ANP
1500
Max. Effective Stress

200
1000
0
0 10 20 30 40 50 60
Time 500
Temperature history
0
0 10 20 30 40 50 60
Time
Max. Effective Stress history

Summary
♦ EP mixed Element is more accurate for:

• Heat treat simulations,
• Springback/ Machining distortion simulations which are driven by the residual
stress field
♦ EP standard Element is faster and has less convergence problem
for:
• Large deformation
• Large size model

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Design Environment for FORMing

Spring 2011 User’s Group Meeting

• 10:30 A DEFORM Activities

• 3:00 P Coffee Break

• 7:30 A Continental Breakfast

♦ Supported Platforms & Compilers

♦ Operating Systems Compilers

Dr. Alexander Bandar (ABandar@deform.com) Material Model

Mr. Harigopal Polisetty (HPolisetty@deform.com) Pre, Post & GUI

Prof. Soo-Ik Oh Senior Advisor

♦ Staff members with strong background in FEM & Metal forming

♦ Staff members with strong background in Material Modeling.

♦ November 8-9, 2011 @ Columbus, OH

♦ Memory leak issue with 64 bit FEM engine (reported in v10.1sp2

♦ 2D Multi-frequencies Induction Heating

Hot Switching Combined

Extract geometry from imported object

Messages: object is loaded

Allow import objects from 2D DB

Conversion also takes care of

Shear Stress (Ksi)

(b) Loading 2 (after yielding,t=10sec)

Larger diameter (1) Larger diameter (2)

Remesh Time (Extended Memory Allocation)

1200 201 143 117 111

•Improved state variable display

Office of Naval Research STTR Contract: N00014-10-M-0264

Air Force STTR Contract: FA9550-09-C-0056

Program Manager: Dr. Rollie Dutton

(The Next Generation)

♦ Integrated Multiple Operation (MO)

♦ Platform for future simulation trends

Geometry Microstructure Properties Residual Stress

Cogging Forging Heat Treat Machining Spin

Cogging Shape Cooling Machining Mission

♦ Restructure existing MO, Cogging, Heat treatment,

• Multiple Forming processes

• Single Forming process

• Heat Transfer Operation

• Multiple heat up/cool down

• Multiple Machining Operations

• Single Machining Operation

♦ Fast input preparation

Manager Operation Editor Property

♦ Items are managed by Manager

♦ By using <id> concept, we can easily

♦ It will be useful to check input data or

♦ One MO project can have multiple sub-

• Multiple heat up/cool down

HT Express Carburization Quenching Tempering

• Multiple Heat Transfer Operations

• Furnace model: HT Batch Furnace

qfan mass Parts

ENVTMP 10, Ndata

Ndata., GFDimN, FtypeN, NsetN, NdimN

Section 3 - geometry data of furnace: OVL

Section 16 - number of layers of furnace wall :

Work Space Atmosphere

Section 6 - cooling system: OPENA

*Notes – material section FFCWRT

Section 15 - material number of furnace

Section 4 - PID parameters:

Section 11 - thermal schedule,

• Load pattern will be