COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES The simulation systems as...
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Transcript of COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES The simulation systems as...
COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES
The simulation systems as
computer support in design of non-
cutting process request the choice
of suitable principles and methods
for the problem solution
OPTIMALISATION PRINCIPLES OF PROCESS DESIGN IN FORGING
AREA rapid and cost effective process design in preproduction stage, application of forging process simulation to eliminate defect,
predict failures in relation product – tools, computer simulation (virtualisation).
COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES
The key technical problems in designing and developing of forging process:
billet material(shape and size, chemical composition and microstructure), flowing properties under processing conditions (stress as function of strain, strain rate and temperature), tool - dies (geometry, surface conditions, material hardness, surface coating, stiffness), interface conditions (lubrication, friction, heat transfer, rigidity production rate force and energy characteristic
APPLICATION OF PROCESS VIRTUALISATION (In forging process the workpiece generally undergoes large
plastic deformation and the relative motion between the deforming semiproduct and the dies’ surface is significant. )
COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES
Key problems in modelling process:
properly selection of the coordinate system,
definition of the starting mesh (FEM),
definition of the mesh density ( mesh density should conform to
geometrical features of the workpiece at each step of deformation),
definition of new mesh (remeshing) and the date interpolation
from the old mesh to the new mesh in order to obtain accurate
result,
definition of fixed displacement and points (nodes, …) of loading,
etc.
podmienky.exe
Geometric propertiesMaterial properties
COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES
Geometric properties: thickness, /hrúbka/ cross section area,/prierez – plocha prierezu/ shear correction /v súvislosti so šmykom, zmena tvaru strižnej plochy/.
Between key material properties it is possible to include:
young’s module, / Hook-E=б/Є (210000MPa pre oceľ, MPa=N/mm2)/
Poisson’s ratio / podiel merného tepla pri stálom tlaku a merného tepla pri stálom
objeme /,
mass density, etc.
Examples of results visualization
COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES
Plotting style /formy vizualizácie/:
Contour lines (show lines along path of equal
interpolated nodal values /interpolácia – metóda
približného výpočtu/), Contour bands (areas of equal interpolated nodal
values), Numerics (numerical values are shown at nodes), etc. visualizácia
CONCLUSION
COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES
detail analyse of task
(consider
specific of non-cutting technologies) choice of suitable software for
simulation
(Marc/Autoforge, SuperForm, Deform,
etc.) analyse of input dates
(material properties, boundary
conditions, etc.) choise of optimal results presentation
(plot,
animation ...)
Conditions for resumption of optimal simulation result