DEFORM 3D v10.

Shape Rolling System Manual

SFTC
07-01-2009

Shape Rolling Template

Objective:
The objective of this document is to provide a brief overview of the interface of Shape Rolling template.

System:
A listing of the system overview is as follows:

1. The work piece or rolling stock is object 1; rolls and other components are the following objects. 2. The rolling stock is of rigid-plastic type. 3. Model preview is available for interactive setup of multi pass conditions. 4. The rolls are rigid objects during the rolling simulations. 5. Rigid rolls can handle non-isothermal conditions. 6. Meshing controls, and remesh procedures for brick elements. 7. Mapped meshing with density control. 8. The rolling direction is along global X-axis. 9. Side rolls can be defined with specific movement controls. 10. Arbitrary roles can be defined with specific movement controls. 11. Support tables can be defined including thermal interaction with work piece. 12. Automatic stopping criteria for ALE and Lagrangian models 13. Inter pass thermal and strain variations can be modeled. 14. Multistand steady state and transient process modeling 15. Effect of gravity 16. Multiple material layers can be modeled. 17. Parametric modeling of roll pass design as well as user defined geometry handling.

Characteristics:
Project based The Shape Rolling Template is project based in which each simulation will be associated with a project directory. A project can consist of a single operation or contain multiple operations that occur on a single rolled stock. Each operation can be either a change in roll geometry, roll gap, and roll speed, workpiece orientation or a heat transfer operation. User interface The interface is an innovative mixture of an open system and guided user interface. If the user desires, navigation can be sequential, via a list of menus to construct a simulation data; alternatively, the user can access menus in any sequence by selecting any item in a list. Running the simulation and Post-Processing the results is carried out via the standard DEFORM-3D features.

Navigating the Template:

The template is used to construct a simulation, load a step from a previously run simulation, add operations and view summary, message and log files.

Figure 1: A snapshot of the interface showing the step list of a previously run database, the rolls, side rolls, table, and stock and the tree containing a single operation.

Pre-Processor There are several different ways of constructing a simulation. These different ways are:

1. Creating a new problem A directory is generated and the problem can be constructed from scratch. This can be done by selecting New Problem under the File menu (See Figure 2). The step number for this is automatically set as 1. The process setting window, as seen below (See Figure 3), should appear on the screen. This window allows the user to insert operations into the process list.

2. Editing a new problem Open opr button can be used to edit the operational settings. Select the operation for which you want to modify the settings and then click Open opr on button to navigate through settings windows and modify.

3. Adding a new operation Adding a new operation means that the stock is to undergo an additional roll pass or heat transfer. You can add a new operation and use Open opr button to edit the settings of the operation.

Figure 2: Creating a new problem.

The process setting window, as seen below Figure 3, should appear on the screen. This window allows the user to insert various operations into the process list.

Figure 3: The process setting dialog

The layout of the Pre-Processor is classified into 4 sections (see Figure 4). These sections are the display windows, project list window, project record window and the setting modification window.

Display window:

The display window (See Figure 4) is where the rolls and workpiece are viewed and geometric information is displayed. The display window can display the following

information depending on the tab selected. The available tabs are:

Graphic A graphical display of the current project.

Summary A text summary of the current project, listing process conditions, operation information and current step information.

Message A text file that gives detailed information about the last simulation run. In general, only the last few lines are of interest to the user.

Log A text file that gives summary information of the overall progress of the last simulation run. As in the case of the message selection, only the last few lines are generally of interest to the user.

Functions that manipulate the DISPLAY window (such as Pan, Zoom, Magnify, and Rotate) can be activated using icons at the top of the Pre-processor window. These

functions also have easy keyboard/mouse combination hotkeys that allow the user to quickly perform these functions without any excessive button clicking.

Display Icons

Icon

Function Pan

Description The objects in the DISPLAY window can be dynamically panned up, down, left, or right by moving the mouse while holding the left mouse button. (Shortcut: Shift + Left Mouse Button)

Zoom

The DISPLAY window can be dynamically zoomed in or out by holding the left mouse button and moving the mouse up or down. (Shortcut: Alt + Left Mouse Button)

Magnify

A portion of the DISPLAY window can to be magnified by clicking and holding the left mouse button at one corner of the zoom box and dragging the cursor to create a window encompassing the zoom area. (Shortcut: Ctrl + Alt + Left Mouse Button)

Rotate (unconstrained) The objects in the DISPLAY window can undergo an unconstrained rotation by holding the left mouse button. (Shortcut: Ctrl + Left Mouse Button)

Rotation about X-axis This icon allows the objects to be rotated about the X-axis in either the Object or Screen coordinate system.

Rotation about Y-axis This icon allows the objects to be rotated about the Y-axis in either the Object or Screen coordinate system.

Rotation about Z-axis

This icon allows the objects to be rotated about the Z-axis in either the Object or Screen coordinate system.

View Orientation Icons Isometric View

YZ Plane View

X-axis either pointing out of the screen (+) or into the screen (-)

XZ Plane View

Y-axis either pointing out of the screen (+) or into the screen (-)

XY Plane View

Z-axis either pointing out of the screen (+) or into the screen (-)

Figure 4: The display window of Shape Rolling.

Figure 5: The display window tabs are highlighted by the red box.

Project list window The project list window can be seen in Figure 6. The purpose of this window is to provide a systematic list of required data for a given simulation. The data in the list is edited in the setting modification window (See Figure 9). The data that is being edited is controlled by the current active position within the project list window. An example of an active project list window is seen in Figure 7. The structure of the program will progress directly down this list by clicking Next in each menu. Alternatively, if any data needs to be modified, clicking at a given item in the list will allow that item to be edited in the setting modification window (See Figure9).

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Figure 6: The project list window. This shows the list that contains sets of simulation condition information.

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Figure 7: An active project list window.

Project record window

The project record window displays the information of the steps before entering into pre or post processor. Any step can be selected to see the results in post processor or modify the settings in preprocessor. Once an operation is opened for modification, the project record window shows a status dialogue.

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Figure 8: The project record window. This will show the current step of the simulation or status dialogue. Setting modification window As the project is being constructed most of the information is specified in the setting modification window (See Figure 9). Clicking Next in this window will allow the user to traverse the project list in order. Each window will have an effect on how the simulation performs. There are a number of different ways in which information is inputted into the simulation. The different types of input are: Radio buttons require something to be specified. For example, in Figure 10, the meshing parameter needs to be specified. The available choices in this case are uniform thickness of layers and finer mesh in the contact region

Action labels appear as blue text. As seen in Figure 11, the action label generates a 3D mesh in the workpiece.
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Buttons used to navigate back and forth in the project list and for advanced geometry setup and opening/closing operations. Figure 11 shows the buttons used to navigate back and forth in the project list.

Checkboxes activate optional settings such as adding objects or parameters. In Figure 11, a checkbox allows the user to select additional side rolls, a pusher and if quarter symmetry is to be used.

Lists used when there are many available selections as in the case of material selection.

Figure 9: The setting modification window. This will show where data is set for a given simulation.

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Figure 10: Window showing different options for roll and table setup

Figure 11: Window showing different options for meshing.

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Rolling type

The rolling template has two different rolling types. One is steady state ALE rolling and other is Lagrangian (incremental) rolling.

Figure 12: Rolling type selection window

Thermal Calculations

In thermal calculations page (see Figure 13) options are available for selecting Calculations in workpiece alone or even in rolls in case of non-isothermal or at constant temperature in case of isothermal models depending on the process and requirement.

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Figure 13: Thermal calculations selection page.

Model Type and Roll Stand

In model type page (See Figure 14) depending on the problem we have options to select full model or half symmetry or one-sixth symmetry.

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Figure 14: Selection of model type and number of roll stands.

Multiple Pass roll Stand Multiple Pass roll stand is new option in which has been added in shape rolling operation both in ALE as well as Lagrangian process type. Multiple pass roll stand is used to deform the billet or bloom by passing it in a series of rolls. The number of roll stands required in a pass to set up the process can be selected. The user can also specify the distance between the roll stands. A typical multiple roll pass setup with 9 stand is done by using 32 rolls used to deform a circular bloom into I-section is design by using full mode type and is as shown below in Figure 15.

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Figure 15: Typical Multiple Pass Roll Design with 9 stands by using 32 rolls.

Basic steps followed in setting up the multiple pass roll design. Select suitable model type and define the number of passes required with specific distance between the passes in such a way that the rolls should not intersect with each other. Select suitable roll stand (See Figure 16) and design rolls by using primitive roll pass designs. Once roll pass designing is done define the movement controls. If the user wants to calculate the temperature for the rolls along with work piece then rolls has to be meshed and material has to be defined. Next rolls have to be positioned accordingly to the work piece. How ever the rolls get automatically positioned in ALE, but the user has to do manual positioning in Lagrangian type.
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Roll pass design

This roll pass design feature enables us to define the different roll designs for main and side rolls. Several pre-defined roll designs are available for user to select else user has an option to create rolls from primitives (Figure 16, 17). Apart from these user can also load 2D cross section geometry data for the roll to define the 3D roll geometry. When roll geometry is not created from the available primitives, it is important to pay attention to the cross section, the roll center and roll diameter data. Octagon and Kocks Mills2 are the two new types of roll pass designs which are added to the list.

Figure 16: Roll Pass design

Arbitrary Roles Arbitrary roles are used for the problems in which the rolls are positioned to meet special requirements. These rolls can be placed at any arbitrary position in space by specifying the orientation of the roll.

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Basic steps followed in setting up the arbitrary roll design. Select arbitrary rolls option in roll stand and define the number of rolls required as per requirement (See Figure 16). Select primitive roll pass designs (See Figure 17) and define required rotation angle to create the arbitrary roll (See Figure 18). A typical roll pass setup with 4 stand is done by using kocks roll pass design by using full mode type and is as shown below in Figure 19. For further examples of arbitrary roles see Figure 19.

Figure 17: Roll Pass design window.

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Figure 18 : Roll Pass design window for arbitrary rolls.

Three roll set (kocks roll)

Arbitrary roll set (Eight rolls)

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Arbitrary roll set (Four rolls)

Typical Arbitrary Roll Pass Design with 4 stands by using Kocks mill. Figure 19 : Arbitrary Roll Pass design examples.

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Workpiece length

User can define the length of the stock or can use the default length set by system (see Figure 20).

Figure 20: Workpiece length definition

Geometry-2D

The sectional geometry of the stock can be imported from a file or can be created from the primitives. The modifications to the imported or created geometry can be made using Edit 2D geometry option. The geometry can be saved using Save 2D geometry option.

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Figure 21: 2D geometry cross-section and Geometry Primitive definition page.

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Geometry Edit

The Geometry editing window is used to create, modify, or view the geometry of a given object. The window appears upon selecting the edit tab in the Geometry window as seen in Figure 22.

Figure 22: Geometry Editing Window

In this window, the geometry can be edited with tools located in the lower-right corner of the screen as seen in Figure 23. The following capabilities are available:

Pick point: This allows the user to pick any available points. Add point: This adds a point after the currently highlighted point in the editing window. Relocate point: This allows the user to select a geometry point and drag it to a different point with the mouse. Renumber point: This allows the user to select a geometry point and make it the first point in the geometry list. Multi-select: This option allows the user to window drag select multiple geometry points. Delete currently selected point: This option allows the user to delete currently selected geometry point.

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Show point order: This option allows the user to show the order of points arranged in a clockwise direction. Show geometry inside mark: This will allow the inside of the object to be shaded. If the orientation is inside. Move to centerline: This forces the geometry to move directly in the x-direction until the left-most geometry point is placed on the centerline. Flip geometry: This allows the user to mirror the geometry about the y-axis. Reverse point order: This reverses the order of points arranged in a clockwise direction. Check geometry: This icon opens the check and correct geometry page.

Figure 23: Geometry Editing Tools Edit 2D Topology

This application is used to define Vertex, Edge, Loop, Region topology entities to the data structure and material groups for 2D mesh. Figure 24 shows the relation between the vertex, edge, loop and relation. If the user imports open boundary objects, the user needs to define the loops and regions for them and then assign the material (See Figure 27). If the user imports closed boundary objects, the loop are assigned automatically, the user needs to assign the region and the material to the particular region. (See Figure 28)

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As a default, Loops and regions are automatically generated for most common cases when only one region exists. If there are more than two loops user needs to define regions interactively. (See Figure 25 and Figure 26)

Figure 24: Relation between Vertex, Edge, Loop and Region .

Figure 25: Loop Definition page

Figure 26: Region Definition page

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Figure 27: Topology example for Open loop boundary object.

Figure 28: Topology example for closed loop boundary object.

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Multiple boundaries

It is possible to create an object with multiple internal holes in the 2D preprocessor. Geometry can be entered for each surface in the X,Y,R format or by importing IGES or dxf format files. The point numbering for the hole geometry must be clockwise, opposite the normal DEFORM numbering system. The Check Geometry feature will ensure that objects are oriented properly relative to each other. However, the outside object must still be oriented properly. (See Figure 29)

Figure 29: Edit Geometrical Boundaries page

Geometry 3D

In this template a 2D geometry will be revolved depending on the model set up in number of objects page to create 3D geometry. In Geometry 3D page the user can see the digitized 2D geometry that will be used to create 3D geometry using preview digitized 2D geometry option. The user has an option to create 3D geometry with finer polygons at the contact or uniform geometry through out the object.

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Figure 30: 3D geometry definition page

Meshing

A 2D cross section mesh will be created which will be extruded / revolved to the length of the object. Number of layers can be increased to have finer mesh in 3D. The fine mesh can be controlled by entering starting and ending points of the desired region. (See Figure 30)

Advanced 2D mesh controls System set-up method uses a system of weights and assigned windows to control the size of elements during the initial mesh generation and subsequent automatic remeshing.

Number of elements (MGNELM) The number of mesh elements represents the approximate number of elements that will be generated by the system. The Automatic Mesh Generator (AMG) takes the value for MGNELM and generates a mesh that will contain approximately the same number of elements. The error between the number of specified elements and the number of generated elements is typically about 10%. When the mesh is generated, the specified

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total number of elements is used in conjunction with the "Point" and "Parameter" controls to determine the mesh density.

Element size ratio (MGSIZR) The maximum size ratio between elements is one of several ways to control the mesh density during automatic mesh generation (AMG) by specifying the ratio of node densities. For a value of 3 for MGSIZR, the largest element edge on an object will be roughly 3 times the size of the smallest element edge on the same object. If equal sized elements are desired, then Size Ratio = 1. If Size Ratio = 0, the element size ratio will not be a factor in the mesh density distribution.

Number of thickness elements (MGTELM) The max thickness ratio is one of several ways to control the mesh density during automatic mesh generation (AMG). The number of elements in thickness direction represents the approximate number of elements that will be generated by the system across the thickness direction of any region of the part. The Automatic Mesh Generator (AMG) takes the value for MGTELM and generates a mesh that will have that number of elements across the thinnest portion.

Grid resolution (MGGRID) When an object is meshed in 2D, a sampling grid is required to discretize density of the mesh throughout the starting geometry. Grid resolution specifies the spacing of the sampling grids that are used to sample mesh densities. Increasing the value of X division or Y division will result in sharper gradients between areas of differing mesh density. In the case of blanking, where a very high mesh gradient is required over a narrow region, these values may need to increase to capture high changes in mesh gradient over short distances.

Node addition parameters (MGERR) The node addition parameters specify the maximum distance and angle error permitted between the object boundary and its associated grid element side. The distance and angle

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tolerances are used to capture critical boundary geometry that might otherwise be lost when the mesh is generated. If an object is required to capture very small features, the maximum distance can be decreased or if a node needs to be placed on a shallow angle, the angle error can be de-creased as well. Rarely will the user ever have to change these values. For parts that are very small, a value of 0.01% of the objects bounding box is a good starting number that can be used for MGERR for better handling of mesh resolution. Mesh weighting factors The weighting factors or parameters (system defined mesh density) for boundary curvature, temperature, strain and strain rate specify relative mesh density weights to be assigned to the associated parameter (Figure 31).Temperature, strain, and strain rate densities are assigned based on gradients in these parameters, not absolute parameter values. That is, a region with a rapid temperature change in a particular direction will receive more elements that a region with a uniform high temperature.

Boundary curvature based weighting factor (MGWCUV) The Boundary Curvature weighting will apply a higher mesh density to curves on the objects boundary. If MGWCUV is greater than 0, the boundary area with curves will receive a higher mesh density in that area. If MGWCUV is set to 0, this weighting criterion is ignored. The values from all the mesh density keywords are combined during the mesh generation process to create a mesh density distribution within the geometric boundary.

Strain base weighting factor (MGWSTN) To keep a fine mesh in areas of high strain this weight can be adjusted.

Strain rate based weighting factor (MGWSTR) If there are areas on the deforming object which see high strain rates and localized deformation then using this weight will put a fine mesh in areas where there is a high strain rate gradient

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Temperature based weighting factor (MGWTMP) This weight can be used to specify fine elements in areas of high temperature gradients.

Figure 31: Advanced 2D cross section mesh generation window

The Mesh Generation window (Figure 32) allows the user to generate a mesh for the current object.

Figure 32: Mesh Generation Page.

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Figure 33: Workpiece generated with uniform thickness of layers option.

Figure 34: Workpiece generated with finer mesh option.

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Mesh generation

When all of the Mesh parameters have been set, a mesh can be generated by clicking on the Generate button. The user can either generate uniform mesh or finer mesh based upon the rolling operation selected. Finer meshing parameter are mainly used for steady state ALE problems, for accurate definition of the deforming region (contact and material flow). Figure 33 and Figure 34 shows the difference in mesh regions. When a new mesh is generated for an object that currently has a mesh, the old mesh will be deleted and replaced with the new mesh.

Mapped Mesh Generation This option allows the user to generate the mesh in an uniform way. Previously the mesh was generating based on Boolean methodology, but now with the help of MAPLST.DAT file the user can get a controlled mapped meshing (See Figure 35). This option allows to user to control the density of mapped mesh. (See Figure 36)

Figure 35: Mapped and Non-mapped mesh.

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Difference in generating in generating mapped mesh and non-mapped mesh is shown in Figure 36. It can be see that the mapped mesh can be generated only when there is MAPLST.DAT file in the working directory.

Figure 35: Generation of Mapped and Non-mapped mesh.

In the above 2 examples shown in Figure 35 for Boolean methodology, 1. thickness elements 10 and size ratio 2 2. thickness elements 7 and size ratio 2 In the first example the cross section is square hence the model has applied same number of elements in both X and Y direction. In the second example the thickness elements has been applied to shorter length of the cross section and for the lengthier side it has multiplied with the size ratio. Mapped Mesh Generation for Thin Sections The user can generate a mesh with well-controlled density of mesh using MAPLST.DAT. One such example of is shown below (See Figure 36). Parameters of the MAP.DST file are: First column gives the density point location. Second column gives the length. Third column gives the Mesh density.

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In Case A at point 1 at length 0 the mesh density will be 1 similarly at point 2 at a length of 0.5 the mesh density will be 5. User can easily make out the variation in mesh density in both the cases.

Figure 36: Generation of Mapped Mesh for thin sections.

The 3D mesh of the above cross section is as shown below in Figure 37. This section is used for simple flat rolling with a thickness of 0.4 in and width of 8 in.

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Figure 37: Controlled 3D Mapped Mesh Generation.

Review of Initial ALE Mesh Methodologyfor thin sections Initial ALE Mesh review can be done in following methodologies as explained below (See Figure 38). Boolean Method: In which the workpiece walls become too thin after passing through the rolls. The exit cross section is the result of Boolean of roll gap and workpiece. Thin Section Method: It provides a better initial mesh for the work piece at vertical wall cases. In this methodology the section of the workpiece is adjusted to the roll gap without Boolean.

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Figure 38: Review of Initial ALE Mesh with different methodologies.

Boundary conditions

Boundary conditions specify how the boundary of an object interacts with other objects and with the environment. The most commonly used boundary conditions are heat exchange with the environment for simulations involving heat transfer, prescribed velocity for enforcing symmetry or prescribing movement. The boundary conditions for workpiece and rolls are automatically assigned. If user wants to change the boundary conditions, he can modify the boundary conditions.

Figure 39: Boundary condition page

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Movement control

The movement for rolls can be specified either by Angular Velocity or Torque. In steady state ALE type rolling operation only constant movement can be used, while constant, function of time or function of angle movement control can be used for Lagrangian type rolling operation. The user can preview the movement of the rolls using the preview movement option.

Figure 40: Movement controls of rolls

Note: Please close the preview movement window before navigating away from the movement page.

Stopping criteria

Stopping criteria to stop the rolling process can be specified by setting a co-ordinate in +X or X direction (rolling direction), after all nodes of workpiece cross the particular

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defined point (imaginary plane) the simulation stops for that pass. Stopping criteria option is available in lagrangian (incremental) rolling only while in ALE the simulation will be automatically stopped once the steady state is reached with respect to diminishing gradients of the state variables and the geometry corrections reaching the exit section.

Figure 41: Stopping criteria definition.

Entry cross section mesh from last operation

For easy and automatic setup of multi pass models, where in the workpiece shape may not remain straight as it heads to generate the data needed for the subsequent pass. This kind of workpiece distortion could be a result of basic roll pass design, and table position as well. This feature attempts to automatically generate data with correct alignment of deformed workpiece from one pass to the next in case of Lagrangian model. The use can either use the cross section at exit option or the cross section at last roll contact option as shown in Figure 42.

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Scale strain to simulate retained strain between passes

This functionality allows user to define a table data of strain and retained strain, where by user can scale (or map) the end results of one pass (strain) while preparing the data for the subsequent pass. This will enable users to model the process conditions like strain recovery at high temperatures,(when users have the measured data) when there is a definite heat transfer time between two rolling passes, and inter pass strain reduction needs to be accounted for. Figure 42 and Figure 43 shows the strain scaling function option enabled to simulate the retained strain between passes and strain scaling function window to define retained strain values.

Figure 42: Strain scaling function to simulate retained strain between passes.

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Figure 43: Strain Scaling Function Window

Use thin section meshing

This option is mainly used for meshing thin section geometries, so as to retain the structure of the mesh when the significant deformation is more than the thickness of the thin section object. Please refer the section of mapped mesh generation for thin sections

Meshing between passes

User can force remesh of the stock by selecting the option Force remeshing.

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Figure 44: Meshing between passes

Boolean between passes

This operation allows the user to control the regions of interest and the model size across multiple passes in a typical transient rolling process. In Lagrangian operation as the stock or workpiece moves from one pass to another, its length increases. Mesh system used in the initial passes may soon become less effective to handle contact conditions in the subsequent passes due to the element stretching in the deforming region. Finer mesh from the start of the passes could be computationally more expensive. By using this Boolean operation the user can select an area of interest in the rolling direction and periodically delete the workpiece that is stretched beyond this domain during rolling process. For example if the end effects are not required to be modeled, user can trim the end regions after a set number of passes while maintaining good contact and material flow description with a model size that is computationally efficient. This can be done using the different options available as given below (Figure 45).

When S1 is 0, the front end mesh will be kept. When S2 is 1, the rear end mesh will be kept. 0 keep the original mesh between S1 and S2 1 project the nodes at front end and read end to a plane

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2 smooth the axial coordinate for the points between the front and rear ends. 3 use specified axial location to sample the nodes

Figure 45: Boolean between the passes

Scheduled Positioning

Scheduled positioning page can only be seen in Lagrangian Incremental Rolling type, while defining multiple passes. The scheduled positioning is meant for cases where the model objects (like pusher, tables, workpiece and rolls) are required to be repositioned for the subsequent pass. Typical scheduled positioning data could involve a series of positioning steps to accomplish model setup between the passes.

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Figure 46: Object Positioning Page

Figure 47: Adding scheduled positioning during deformation.

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First encountered Scheduled Object Positioning First encountered is a new scheduled object positioning option provided in interference object positioning (See Figure 48). This option allows the user to position the object in such a way that the positioning object will come and position automatically with the object that it encounter first along its moving path. For example if the user has considered the workpiece for positioning along with rolls then user uses the first encounter object positioning option then the work piece will automatically get positioned to rolls as seen if Figure 49. Similarly if the user makes a positioning of the pusher then pusher will get positioned to work piece automatically as seen in Figure 49.

Figure 48: First encountered object positioning in interference object positioning option.

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Figure 49: First encountered object positioning for work piece and pusher in Lagrangian.

Simulator The standard DEFORM-3D simulator can be used to perform the simulation.

Post-Processor

The standard DEFORM-3D Post-processor can used to view the simulation results.

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