1.1 Problem Setup 1 1.2 Thermal Calculations 2 1.3 Workpiece Shape 3 1.4 Workpiece Geometry 4 1.5 Workpiece Mesh Generation 5 1.6 Material Definition Window 7 1.7 Driving Roll Geometry 8 1.8 Driving Roll Position 11 1.9 Driving Roll Movement Definition 12 1.10 Pressure Roll (Mandrel) Geometry 13 1.11 Pressure Roll (Mandrel) Position 16 1.12 Pressure Roll (Mandrel) Movement Definition 17 1.13 Inter Object Definition 18 1.14 Stopping Controls 19 1.15 Step Controls 20
1.1 Problem Setup
Open DEFORM?-3D. Make a new problem under “Problem” directory. Problem setup window will open. Select the ring rolling guiding template (See Figure 1)
Figure 1: Problem type selection window
Select under problem home directory and name it: ring_rolling_lab2. (See Figure 2)
Figure 2: Assigning the problem name
(Ring rolling preprocessor will open up)
Click “Next” to open operation and name operation “rolling 1” and click “Next”.
1.2 Thermal Calculations
The available options in “Thermal calculations” page are “Calculate temperature in ring only (non-isothermal)” and “Constant temperature (isothermal)”. Use “Constant temperature (isothermal)” in this lab(See Figure 3). Click “Next” to go to the “Workpiece shape” page.
Figure 3: Temperature calculations page
1.3 Workpiece Shape
Select the default “Simulate whole part” in “Workpiece shape” page and click next. (See Figure 4)
Figure 4: Work piece shape selection page
In the “Number of objects” page, Note the current default objects. Click “Next” to go to the “Workpiece – ring” object page. Leave the temperature for the ring at 70 F and click “Next”.
1.4 Workpiece Geometry
In the “Geometry – 2D cross-section” page, Select “Use 2D geometry primitives” and select the hollow cylinder (See Figure 5). Use 2X2 in2 as cross-section with 0.25”as fillet radius and (6, 0) as origin. Create the geometry and close the primitive window.
Figure 5: Creating 2D geometry for the workpiece.
The user also has the options of using Import geometry and/or table inputting/editing 2D geometry (create any primitive geometry to activate this 'Edit 2D Geometry') other than importing 2D geometry.
1.5 Workpiece Mesh Generation
Now, click “Next” to go the mesh generation page. Notice the 2D cross-section is displayed in 3D and the revolving axis for 3D-mesh generation would be the Z-axis.
Use 100 elements for the 2D cross-section mesh and generate the 2D mesh (See Figure 6). There are other parameters for 2D-mesh generation by clicking the “Advanced…” button.
Figure 6: Generating 2D mesh
Use the 200 sections for 3D mesh and generate the ring mesh by clicking “Generate 3D mesh”. (See Figure 7)
Figure 7: Generating 3D mesh
There are display options to turn On/OFF 3D mesh, 2D geo and mesh, and Slicing on the
1.6 Material Definition Window
Click “Next” to go to Material page, and pick AISI-1035 Cold from the material dialog by clicking “import material from library” and selecting “Steel” category (See Figure 8). Then, go to the next page for driving roll definition.
Figure 8: Material selection window.
1.7 Driving Roll Geometry
In the object page, leave object name as driving roll and go to the next page, which is the 2D cross-section geometry page. Click “Use 2D geometry primitive” and select the hollow cylinder. Use 5X10 in2 as cross-section and (14,0) as origin(See Figure 9). Create the geometry and close the primitive window.
Figure 9: Creating 2D cross section for Driving Roll.
Click “Next”, go to the “Geometry 3D” page. Click “Preview digitized 2D geometry” and the imported geometry is discretized and the discrete points are shown (See Figure 10). Use the 100 revolving sections, and generate 3D geometry. (Figure 11)
Figure 10: Preview digitized 2D geometry
Figure 11: Generating 3D geometry
Notice there are options to change digitizing parameters by clicking on the “set up”
button. There are also display options to turn On/Off 2D and 3D geometries.
1.8 Driving Roll Position
Click “Next” to go to the “position” page. Click “Object positioning” to position the driving roll. The ring and the driving roll are displayed in sliced view for better visualization. Choose “offset” as the positioning method. Move the workpiece by 4 inch in Z direction and hit the apply button. (See Figure 12). Once the positioning is done, click OK to exit the positioning dialog. Then, click “Next” to go to the “Movement” page.
Figure 12: Positioning the work piece
1.9 Driving Roll Movement Definition
Select angular velocity and define rotational movement for the driving roll as a constant of 2 rad/sec. Notice a green rotation arrow showing rotational direction in the display window. (See Figure 13)
Figure 13: Assigning rotational movement for the driving roll
1.10 Pressure Roll (Mandrel) Geometry
Click “Next” to go to the object page for pressure roll (Mandrel). Keep the name of pressure roll unchanged and just click “Next” to go to the 2D cross-section geometry page.
Click “Edit 2D geometry” (create any primitive geometry to activate this 'Edit 2D Geometry') and select the cylinder. Use 2X10 in2 as cross-section with the data indicated in XYR format. (See Figure 14)
X Y R
0 0 0
2 0 0
2 4.5 0
2.25 4.75 0.25
2.25 5.25 0.25
2 5.5 0
2 10 0
0 10 0
0 0 0
Figure 14: Creating 2D cross section of pressure roll geometry
Create the geometry and close the primitive window. Go to the 3D geometry page and
generate 3D pressure roll geometry (See Figure 15)
Figure 15: Generating 3D pressure roll geometry
1.11 Pressure Roll (Mandrel) Position
Go to the position page, and use interference positioning and input 0.0001 as interference tolerance and Y as the approach direction to position the pressure roll with the workpiece as the reference. (See Figure 16)
Figure 16: Object positioning window
1.12 Pressure Roll (Mandrel) Movement Definition
Go to the “movement” page and input 0.01 in/sec speed and 0 torque on pressure roll. Use “preview movement” to visualize the movement of the driving roll and pressure roll. (See Figure 17)
Figure 17: Movement control for driving roll
1.13 Inter Object Relation
Click “Next” to go to “Control” page, the select “generate all” to generate contacts between driving roll and the workpiece as well as between pressure roll and the workpiece. (See Figure 18)
Figure 18: Inter object relationship definition window