DEFORM-3D Multiple Operations Lab

MULTIPLE OPERATIONS LAB

1.1.

Creating a New Problem

1.2.

Creating a Furnace Heating Simulation

1.3.

Adding a Heat Transfer Operation

1.4.

Adding a Deformation Operation

12

1.5.

Running the Simulation

22

1.6.

Postprocessing the Simulation

22

DEFORM-3D Multiple Operations Lab

Multiple Operations Lab

1.1. Creating a New Problem
On a unix machine, type DEF_MO3 to open DEFORM-3D Multiple Operations. On a
Windows machine, go to the
button and select DEFORM-3D Multiple Operations
from the menu. The main window will appear, as shown below.

Figure 1. The main window of the DEFORM-3D Multiple

Operations

Create a new problem by either selecting File New Problem or by clicking the New
Project
icon. The PROJECT SETUP window will appear. Type Spike_Forging in the Project
Name space and set the unit system to English.

DEFORM-3D Multiple Operations Lab

Layout of DEFORM-MO3

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 2. The layout of the multiple operations interface

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

DEFORM-3D Multiple Operations Lab

Figure 3. The process setting dialog

1.2. Creating a Furnace Heating Simulation

Drag the Heat Furnace icon into the project list window. This will then add a furnace
heating operation to the beginning of list. To edit this operation, please click the Open opr button
as seen below.

Figure 4. Adding and opening operations

DEFORM-3D Multiple Operations Lab

Click

to accept the default name of this operation. The number of objects

cannot be edited at this time so click the

button.

Figure 5. Adding the objects for simulation

The values in the setting modification window are values for the workpiece. Accept the
defaults and click

Figure 6. Object properties description window

Question: What does the "Read from DB" checkbox mean?

Answer: This tells the system not to define any information for this object.
The data for the object should be obtained from the previous operation
available from the database. In cases where a part is moving through a

DEFORM-3D Multiple Operations Lab

multiple operation progression, each operation should keep the workpiece

from the previous operation.
Click the Import geometry link and select the file Spike_Billet.STL in the LABS
subdirectory where your version of DEFORM-3D is installed and then click
. Go to
advanced properties in workpiece object page. Activate Volume compensation with Active in
FEM. In the meshing window, set the number of elements to 4000, click Generate mesh and
click
. Please note that this mesh is generally coarser than recommended for many
cases and it is set low to expedite the simulation times for this lab.

Figure 7: Meshing options window

At this window, the user is required to define the material properties for the workpiece.
This can be done a variety of ways but in this lab, the material library will be used. Please click
Import material from library and select AISI-1015 and click

DEFORM-3D Multiple Operations Lab

Figure 8: Material selection

In this window we need to define the boundary condition, click on define BCC and select
the heat exchange with environment. Select all the surfaces except symmetry surfaces for heat
exchange with environment and then click on
to add. Select symmetry planes and select the
symmetry surfaces. Close the BCC window and click

DEFORM-3D Multiple Operations Lab

Figure 9: BCC Options for Heat Furnace option

Figure 10: Selecting symmetry planes

DEFORM-3D Multiple Operations Lab

At this time, positioning would not be considered. Since this is a furnace heating
operation, there are no dies and positioning does not have to be considered at this point. Please
click

In this screen, the process parameters for the furnace heating should be defined. These
parameters are the time in the furnace, the temperature of the furnace and the convection
coefficient inside the furnace. Please take the defaults for all three and click

Figure 11: Process parameters options for Heat Furnace option

In this window, the number of simulation steps and the step increment to save is defined.
Enter the number of steps to 1000 with constant time increment 3.6 sec per step and
click

Figure 12: Simulation controls for Heat Furnace option

DEFORM-3D Multiple Operations Lab

At this time, please click Check data the database and Generate database. Click the
and close the current operation. User can read in any additional operation specific
data that could not be defined using this general MO3 system using the option Append user
defined keyword file. This data gets included before database generation.

Figure 13: DB generation at options

1.3. Adding a Heat Transfer Operation

At this stage, the furnace heating operation has been generated. At this time, subsequent
operations can be defined before the furnace heating needs to be performed.
Click the
button to open the Process Setting window. Drag the Heat Transfer
icon into the Project View list. Click on the Heat-Transfer operation and Click the Open Opr
button.
The first screen allows the user to name the current operation. Please keep the default
name and click

The current screen allows the user to define the number of objects. In the case of a heat
transfer operation, only the workpiece is modeled. Please click

DEFORM-3D Multiple Operations Lab

Notice that the Read from DB checkbox is checked. This means that the result of the furnace
heating operation will be used for this operation. Please click

Figure 14: Window showing that object has been taken from last operation

The object does not need to be positioned at this time, so click

condition window can be seen. Accept the default values and click

Figure 15: Process setting window for heat transfer operation

. The process
.

DEFORM-3D Multiple Operations Lab

At this time the simulation controls window is seen.

Accept the defaults and click

Figure 16: Simulation controls for Heat Transfer option

In this window, no database should be generated so click the

button.

Question: What does the "Append user defined keyword file" checkbox mean?
Answer: This tells the system to also read an optional keyword file when
automatically setting up this operation. Defining this keyword file in outside the
scope of this lab but it is important to note that this advanced feature allows
special, previously defined options to be applied between simulations.

DEFORM-3D Multiple Operations Lab

Figure 17: Window showing "Append user defined keyword file" option

1.4. Adding a Deformation Operation

At this stage, two operations have been defined. The workpiece is ready to be forged.
Click the
button to open the Process Setting window. Drag the Deformation icon into
the Project View list. Click on the Deformation operation and Click the Open Opr button.
The first screen allows the user to name the current operation. Please keep the default name and
click

Set the number of objects to 3 and then click

DEFORM-3D Multiple Operations Lab

Figure 18. Adding the objects for simulation

Notice that the Read from DB checkbox is checked. This means that the result of the transfer
operation will be used for this operation. Please click

Figure 19: Window showing that object has been taken from last operation

In this window we need to define the movement for the object, since object is going to be
stationary there is no need to edit movement hence click

DEFORM-3D Multiple Operations Lab

At this time, the top die must be added to the simulation. This window defines the basic
object information and also allows the user to import a keyword file. Please click

Question: What does the "Skip this object in this operation" checkbox
mean?
Answer: This tells the system to not apply any information for this object
at this operation. Therefore when the simulation runs, this object will be
empty of information until a later operation.

Figure 20: Window showing skip this object in this operation option

At this point, the user can import the geometry for the top die. Click the Import geometry link
and select the file Spike_TopDie1.STL in the LABS subdirectory where your version of
DEFORM-3D is installed and then click

Generate mesh for the top die with 1500 elements and then click

DEFORM-3D Multiple Operations Lab

Figure 21: Meshing options window

Import material AISI-H13 for the top die from library and then click

Figure 22: Material selection

DEFORM-3D Multiple Operations Lab

This screen allows the movement for the top die to be defined. Please define a velocity of 10
in/sec in the -Z direction by clicking Edit movement and set these values and then
click

Figure 23: Movement control settings

In this window we are going to define Boundary conditions for top die. Under boundary
conditions options select Heat exchange with environment and then select all the surfaces except
symmetry surfaces and then click

to add. Close the BCC window and click

DEFORM-3D Multiple Operations Lab

Figure 24: BCC Options of top die for Deformation

At this time, the user can define basic information for the bottom die. Accept the defaults
. Click the Import geometry link and select the file Spike_BottomDie.STL
and click
in the LABS subdirectory where your version of DEFORM-3D is installed and then
click

..

Generate mesh for the bottom die with default elements number and then click

Select AISI-H13 which is already imported as the material for bottom die and then click
. Since the bottom die is stationary there is no need to edit the movement controls
hence click
. In this window we are going to define Boundary conditions for bottom
die. Under boundary conditions options select Heat exchange with environment and then select all
the surfaces except symmetry surfaces and then click to add. Close the BCC window and click
.

DEFORM-3D Multiple Operations Lab

At this time, the three objects are seen as in Figure 2. Note that the top die needs to be positioned
down into the workpiece and the bottom die needs to be positioned up into the workpiece. The
positioning window can be seen in Figure . The top die and bottom dies have been defined at this
step and can be positioned by offset positioning. However, the workpiece is to be "Read from
DB" and its position at this step is not certain so the positioning can only be scheduled. Click
Add to invoke the object positioning window. Set the top die to position by interference into the
workpiece in the -Z direction and and set the bottom die to position by interference into the
workpiece in the +Z direction. After setting this, click

Figure 25: Scheduled positioning of top die in deformation operation

DEFORM-3D Multiple Operations Lab

Figure 26: Scheduled positioning of bottom die in deformation operation

In this screen, the contact conditions are defined. Please keep the defaults and click

In this screen, stopping controls are defined. Toggle the die stroke value option and define a
stroke of 1" and click

DEFORM-3D Multiple Operations Lab

Figure 27: Stopping controls option

Accept the defaults for the stepping controls and enter a value obtained by dividing 1inch
by number of steps (0.01 in for this case) and click

Figure 28: Simulation controls option

DEFORM-3D Multiple Operations Lab

Click the Next opr button. After defining any of these operations, selecting the operation
name, from the project/operation tree and right mouse click leads to additional options like Add
Cycle which can be used to include trivial repeat operations

Figure 29. The initial object positions for the billet, the top die and the bottom die. Note that the top
die must be positioned downward towards the billet and the bottom die must be positioned upward
towards the billet.

Figure 30. The positioning object window. The Position object option allows the user to position an
object that hasn't been specified as "Read from DB". The scheduled positioning is meant for cases
where the object is "Read from DB" and the final positioning isn't necessarily known at this stage.

DEFORM-3D Multiple Operations Lab

1.5. Running the Simulation

Select Heat furnace option from the project list window, then click on the Simulator tab and click
on Run simulation.

Figure 31. Layout of Multiple operations Simulator

The simulation may take a few minutes to complete. Please wait until it is finished.

1.6. Postprocessing the Simulation

Click on the Post tab and check the simulation has ran correctly. The layout of this the multiple
operations post-processor is very similar to the post-processor of DEFORM-F3.

DEFORM-3D Multiple Operations Lab

Figure 32. Layout of Multiple operations Postprocessor

Figure 33. Temperature distribution after heat furnace operation

DEFORM-3D Multiple Operations Lab

Figure 34. Temperature distribution after heat transfer operation

Figure 35. Workpiece at the end of deformation operation