ALE Extrusion Example -5

ALE EXTRUSION EXAMPLE - 5 (ALE TEE)

1.1.  Creating a New Problem 1 

1.2.  Layout of Extrusion template 1 

1.3.  Defining the Extrusion Process 2 

1.4.  Defining model type and number of objects required 3 

1.5.  Defining workpiece object 4 

1.6.  Defining Die1 object 10 

1.7.  Defining Die2 object 13 

1.8.  Positions the objects. 15 

1.9.  Defining Inter-Object Relations 16 

1.10.  Step control and stopping criteria 18 

1.11.  Running the Simulation and Post-Processing 20 

1.12.  Exiting DEFORM-3D 20 

 ALE Extrusion Example -5

1.1. Creating a New Problem

From the Windows Start menu, select DEFORM 3D Extrusion in DEFORM v11.0 Beta.

1.2. Layout of Extrusion template

The layout of the interface can be seen in the figure below. The screen is distributed into four
discrete sections. The display window is where the objects for the current operation can be
viewed. The project list window is where the list of settings currently editable. Based on the
selection in the project list window, certain values can be edited in the setting modification
window. As information is provided to the interface, information will be printed in the project
record window such as saved steps.

Figure 1: The layout of the Extrusion template interface.

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Select SI units for this Lab and enter Project Name & Title as Tee as shown in Figure 1.
Click the “Next” button.
Specify the Operation Name “Tee_Extrusion”.
Click the “Next” button.

1.3. Defining the Extrusion Process

In Extrusion type page select extrusion type as “ALE EXTRUSION”, (See Figure2).
Click the “Next” button.

Figure 2: ALE Extrusion type.

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In the thermal calculations page, select the "Calculate temperature in workpiece only (non-
isothermal)" option (See Figure 3) as we are not going to calculate the temperature on the dies.
Click Next.

Figure 3: Setting type of thermal calculation

1.4. Defining model type and number of objects required

In model type and number of dies page, there are two options one for full model and other with
symmetry condition. In this lab, we are going to use symmetry condition model hence select with
Symmetry condition and select number of dies as 2 (See Figure 4) as we are going to use one
object for Ram and other for Container.

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Figure 4: Model type and number of dies page.

Note: The Extrusion template supports the guided/open concepts used by many DEFORM
products. At any time during the problem setup, the next or back buttons can be used to
navigate to adjoining windows. In addition, the Project View highlights the current position in
the setup at any time.

1.5. Defining workpiece object

Change the object name as Billet and specify a Billet temperature of 400 C. (See Figure 5) and
click next to define its Geometry.

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Figure 5: Defining workpiece parameters

1.5.1. Import Billet Geometry

Click on “Import geometry”
Open the file “Extrusion_tee_billet.STL” (See Figure 6).
Click on check and correct geometry.

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Figure 6: Import Billet geometry.

1.5.2. Symmetry surface of the Billet

Select the symmetry surface of the Billet (See Figure 7)

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Figure 7: Selecting symmetry plane

1.5.3. Generating Mesh for Billet

The workpiece mesh has the largest influence of all simulation settings on simulation accuracy
and speed. A coarse mesh will allow extremely fast simulation speeds, but surface resolution will
be poor. More mesh elements will enhance surface resolution, but will do so at the expense of
simulation time, for this lab use relative mesh generation method to generate mesh, use the 3
mesh windows which is shown in Figure 8, set the number of elements to 125000 and size ratio
as 30 and also click on generate mesh so that finer mesh get generates in critical regions like exit
region where material exits the die cavity (See Figure 9).

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Figure 8: Mesh window definition.

Figure 9: Detailed setting meshing option.

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1.5.4. Defining Material & BCC for Billet

In Material window, import ALUMINUM 6061 [500-900F(250-480C)] Material from Library

(See Figure 10).

Figure 10: The Material selection page.

In BCC page, View the default symmetry conditions & Heat exchange with environment
surface assigned. The default conditions are correct and now just define free surface BCC for the
Billet as shown in Figure 11, click Next.

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Figure 11: Billet BCC definition.

1.6. Defining Die1 object

Change the object name as Container and specify a Container temperature of 400 C and also
select assign bearing surface check box (See Figure 12) and click next to define its Geometry.

Figure 12: Defining Container parameters

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1.6.1. Import Container Geometry

Click on “Import geometry”
Open the file “Extrusion_tee_Container.STL” (See Figure 13).

Figure 13: Importing container geometry

1.6.2. Symmetry surface and bearing surface definition for container

Click next for geometry page and select the symmetry surface of the container in geometry
symmetry surface page (See Figure 14).

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Figure 14: Defining symmetry surface for container.

Click next for geometry symmetry surface page and define the bearing surface for the container
geometry (See Figure 15), and click next up to Die2 page.

Figure 15: Defining Bearing surface for container.

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1.7. Defining Die2 object

Change the object name as Ram and specify a Ram temperature of 400 C, (See Figure 16) and
click next to define its Geometry.

Figure 16: Defining Ram parameters

1.7.1. Import Ram Geometry

Click on “Import geometry”
Open the file “Extrusion_tee_Ram.STL” (See Figure 17).

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Figure 17: Importing Ram geometry

1.7.2. Symmetry surface for Ram

Click next for geometry page and select the symmetry surface of the Ram in geometry symmetry
surface page (See Figure 18).

Figure 18: Defining symmetry surface for Ram.

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After defining symmetry surface for ram click next up to movement control page to define ram
movement, now define ram movement as Speed 5mm/sec (See Figure 19).

Figure 19: Defining Movement control.

1.8. Positions the objects.

Set the Ram to position by interference into the Billet in the -Z direction, using drag and offset
position method position container with respect to Billet (See Figure 20). After setting this, click
next to go to define inter object data.

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Figure 20: Object position details.

1.9. Defining Inter-Object Relations

In the Generate inter-object relations page (master-slave relations will be automatic). Go to edit
page, define the shear factor as 0.4 and interface heat transfer coefficient as 5 for all the

relations. Click on to calculate contact generation tolerance automatically. Select the

“Generate all” button. The Generated contacts looks as shown in Figure 21.

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Figure 21: Inter-object relationship window.

Figure 22: Contact generation between Dies and workpiece.

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1.10. Step control and stopping criteria

After inter-objects relations, go to step controls and stopping criteria. Set 5000 time steps for this
simulation with a step increment of 100 and set “Time per step” value to 0.001.

Figure 23: Step controls.

Check the data and generate the database. Save the project and close operation.

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Figure 24: Generate database window.

Image of the setup after defining billet, Container and ram data is as shown below in Figure 25.

Figure 25: Image after complete setup in symmetry mode.

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1.11. Running the Simulation and Post-Processing

In GUI main select the DB & under simulator click on Run. The simulation will be started.
Simulation Graphics to see the results simultaneously as simulation runs. Post-Processor can be
used to view the results.

1.12. Exiting DEFORM-3D

Click the Exit icon. Once you are back in the MAIN window, you can exit DEFORM-2D3D

by selecting FileQuit or by clicking . When asked whether you want to quit,

click .

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