Rathmann_4th ICFG Workshop

7/24/2019 Rathmann_4th ICFG Workshop

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Produktionstechnik und Umformmaschinen

Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche

10/06/2004 _tr_1.ppt PtU, Rathmann

Development of a TechnologicalProcessor for 3D-FEA of

Rotary Swaging Processes

T. Rathmann

Institute for Production Engineering and Forming Machines

Darmstadt University of Technology, Germany

Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P.Groche

Shanghai

23 28 May 2004

4th ICFG Workshop on Process Simulation

in the Metal Forming Industry


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Outline

Overview of the rotary swaging process

Experimental Verification

Technological Processor

Process-Simulation


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Introduction - Rotary Swaging

Rotary Swaging is a very efficient cold forming process for forming tubes and bars

Die segments arranged opposite to one another apply radial forces in rapid

succession.

ComponentsPrinciple

source: Felss


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Typical Components

Drive shaft

Hinge shaft

source: Felss

source: Felss

Gearshaft

source: HMP

Homokinetic joint

source: HMP

Rotary Swaging an efficient

cold forming process for forming

tubes and bars


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Rotary Swaging Process principle

Presentation as a sequence


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Process Variations

Infeed-swaging Recess-swaging

without

mandrel

withmandrel


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Problems and Objectives

The process planning has a crucial influence on the economic efficiency of the

process

Planning of stages

Die construction

Setup and adjustment

Die changes (possibly)

Process planning

Based on the knowledge of the staff members

Loss of knowledge if staff leaves employment

Common

Problems

knowledge


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Problems and Objectives

Geometric changes in components cause long try-out-times

Lay-out of rotary swaging machines and equipment is difficult

Increasing requirements concerning quality and accuracy (Net-Shape-Forming)

Complex interrelationships on process defining parameters

Analysis of the rotary swaging process by FEA

Simplif ication of the use of FEA by a technological

processor (as interface)

OBJECTIVES

Technological

Problems


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Postulated Process Planning

Drawing of

workpiece

Toolconstruction

Process Planning assisted by FEA

OK?Yes

NOK(up to now)

Try-Out

New parameters


Modelling

Simulation

Analysis of the resul ts


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ProcessProcess--SimulationSimulation


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FEA-sequence up to now

MSC.Marc

Mentat

MSC.Marc

MSC.Marc

Mentat

Subroutine

FE-Knowledges required in

all steps

THE MARC SYSTEM

Preprocessing 80160 h

Time requirements

1

Steps

START

Analysis 5-500 h2

Postprocessing 5 h3END


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Problems of simulation of rotary swaging processes

3D3D--ModellingModelling High element numbersHigh element numbers

Representation of complex tool kinematicsRepresentation of complex tool kinematics

Contact changes in a high frequencyContact changes in a high frequency

High numbers of iterationsHigh numbers of iterations

Convergence

Computing time

Particularities concerning the simulation of rotary swaging processes

Incremental forming operation with 100 to 300 cycles

Tool-separation in every cycle

3D-Modelling required

rdie > rwp

work-

piece

die

problems


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Design of the Rotary swaging FEA-model

Representation of the tools by Rigid Bodies

Representation of the workpiece with 8-node

isoparametric 3D hexahedrons

Realisation of the relative movement between

die and workpiece only by the tools

No rigid body movement of the workpiece

Simplified evaluation

Easier implementation of analysis modules in the

technological processor

Advantages


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Use of cyclic symmetry

Possibility to reduce computing time (saving of time ~ )

Corresponding results (difference < 0,04%)

4-fold segmented tools Quarter-model

Reducing element numbers


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Examination of convergence

Maximalkraft

0

100

200

300

400

500

600

700

2D Grob 2D Mittel 2D Fein 3D Grob 3D Mittel 3D Fein Experiment

Netz

Radialkraft[kN]

2D 3D Exp.

Influence of spatial discretisationMax. radial force Frad

Representation of die movement

Objective: Reduction of element- and increment numbers

T

TDC

BDC

grid

radialfo

rce[kN]


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FE-Analysis

Adjustable Process parameters of machinery

Stroking frequency fsw

Rotational speed of external/internal rotor ne/ni

Axial rate of feed vax (Infeed swaging)

Radial rate of feed vrad (Recess swaging)

Rate of feed + Stroking frequency fsw Feed per pass vx,P

Rotational speed ni + Stroking frequency fsw Angle of rotation per pass P

Technological quantities


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Influence of the technological quantities

Einfluss des Drehwinkels pr o Hub

ESoD; v rad/Hub=0,0074=konst.

0

20

40

60

80

100

120

2,4 3,36 4,8 5,6 9,06 13,2 18,85 22Drehwinkel pro Hub []

Kraft[kN]

Fradmax [kN]

Faxmax [kN]

Einfluss des Axialvorschubes

VSoD (Drehwin kel pro Hub = 12 = kon st.)

0

20

40

60

80

100

120

140

0,012 0,017 0,028 0,048 0,091 0,167 0,278

Axialvor schu b pro Hub [ mm]

Kraft[kN]

Fradmax [kN]

Faxmax [kN]

0 10 20 30 40 50 60Weg [mm]

0

25000

50000

75000

100000

125000

150000

Frad[N]

0 10 20 30 40 50 60

Weg [mm]

0

2500

5000

7500

10000

12500

15000

Fax[N]

T:\Rundkneten\Vorschub\180703\5\fort.25.

Knetfrequenz: 30 [Hz]

3D Simulation

Kraftverlauf beim Vorschubrundkneten

Vorschubgeschwindigkeit: 0.05 [m/min]

max. Radialkraft : 126.1 [kN]

max. Axialkraft: 7.1 [kN]

Drehwinkel pro Hub: 13.6 []

Axialvorschub pro Hub: 0.03 [mm] Gittertyp: G2

Drehvorschub: 68 [1/min]

Maschinendaten Technologische Gren

HSS-Diskretisierung: 7 [Inc/Hub]

ohne Dorn

Simulationsspez. Angaben

Evaluation by comparing the maximum

occuring axial and radial forces

Force progression(Feed swaging without mandrel)

max. radial force: 126,1 kN

max. axial force: 7,1 kN

Influence of angle of rotation per passRSwoM; vrad/pass=0,07=const.

Influence of axial rate of feed per passFSwoM; P = 12 = const.

Angle of rotation per pass []

Axial feed per pass [mm]

Force

[kN]

Force[kN]

Swaging Frequency: 30 Hz

Axial rate of feed: 0,164 m/min

Rotating speed: 60 1/min

Process Parameters

Angle of rotation per pass: 12

Axial feed per pass: 0,09 mm

Technological Quantities

Increments per pass: 7

Grid-type: G2

FE-specific quantities

path [mm]

path [mm]


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0 10 20 30 40 50 60 70 80Lnge [mm]

9

10

11

12

13

14

15

16

R

adius[mm]

3

3.1

3.2

3.3

3.4

3.5

Wa

ndstrke[mm

]

T:\Rundkneten\Vorschub\040503\3\okr_dispyz.


3D Simulation

Wandstrkeverlauf beim Vorschubrundkneten



Axialvorschub pro Hub: 0.09 [mm] Gittertyp: G2




ohne Dorn


Influence of the technological quantities

Evaluation by comparing the maximum

evaluated wall thickness (in the zone of

calibration) Einfluss des Drehwinkels pro HubESoD; v rad /Hub = 0,0074mm = konst.

3,24

3,26

3,28

3,3

3,32

3,34

2,4 3,36 4,8 5,6 9,06 13,2 18,85 22

Drehwinkel pro Hub []

max.

Wandstrkeim

Kalibrierereich[mm]

Einfluss des Axialvorschubes

VSoD (Drehwinkel pr o Hub = 12 = kons t.)

3,26

3,28

3,3

3,32

3,34

3,36

3,38

0,012 0,017 0,028 0,048 0,091 0,167 0,278

Axialvor sc hub p ro Hub [mm]

max.

Wand

strkeim

Kalibrierbereich[mm]

Course of wall thickness(Feed swaging without mandrel)

Influence of angle of rotation per passRSwoM; vrad/pass=0,07=const.

Influence of axial rate of feed per passFSwoM; P = 12 = const .

Angle of rotation per pass []

Axial rate of feed per pass [mm]

M

ax.wallthickness[mm]

Max.wallthickness[mm]


Axial rate of feed: 0,164 m/minRotating speed: 60 1/min

Process Parameters





Grid-type: G2


wallthickn

ess[mm]

path [mm]


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ExperimentExperimentaal Verificationl Verification


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Possibilities of Verification

S

I

MU

L

AT

I

ON

E

X

PE

R

IM

E

NT

Grain structure

Geometry

Force-measurement

0 5 10 15 20 25Zeit [s]

-2.5

0

2.5

5

7.5

10

Fax[kN]

0 5 10 15 20 25Zeit [s]

-25

0

25

50

75

100

Frad[kN]

Dateiname: V7_1.dat

Knetfrequenz (IST): 33 HzWerkstoff: 16 MnCr5 (1.7131)

Kraftverlauf beim Einstechrundkneten ohne Dorn

Abmessungen (L/D/s)[mm] : 330/30/3 Abtastrate: 3 kHz

Drehzahl Knetwelle : 110 1/minBemerkung: : -

Micro hardness

Plastic strain


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Metrology

Measurement of radial forces

Base jaw with integrated

force transducers

Front plate with adapted

telemetrical transmitter

Wireless transmission required

Telemetry

(rotating swaging shaft)

High sampling rates due to high swaging

frequencies (100 ... 300 measurements/pass)

Swaging shaft

Outer rotor


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Transmission of signals by wire

Metrology

Measurement of axial forces

force transducer

clamping unit


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0 5 10 15 20 25Zeit [s]

-2.5

0

2.5

5

7.5

10

Fax

[kN]

0 5 10 15 20 25Zeit [s]

-25

0

25

50

75

100

Fra

d[kN]

Dateiname: V7_1.dat


Kraftverlauf beim Einstechrundkneten ohne Dorn



Results of measurements

Force progression (Recess swaging without mandrel)

Material: 16MnCr5

Dimensions: (D/L/Wt)[mm] 330/30/3

Stroking frequency (actual): 33 Hz

Sampling rate: 3 kHz

Swaging shaft: 110 rpm

time

time

Radial speed rate (20 mm/min)3s

calibration

20.4 20.425 20.45 20.475Zeit [s]

0

10

20

30

40

50

60

F_rad[kN]

Dateiname: V1_2_a.dat


Einzelschlagdarstellung F_rad



fsw

Resolution of single strokes Frad


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TechnologicalTechnological ProcessorProcessor


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Technological Processor (TP)

To allow 3D-FEA of rotary swaging processes

for normal users without FE-knowledges

To evaluate and represent the results:- Forces

- Geometric parameters (diameter, elongation, course of wall thickness)

- Parameters of forming technology (stress, strain)

To simplify the input of all necessary input data:

- Process parameters

- Tool parameters- Semi finished product data

To carry out the simulation in background

What are the intentions?

Main objective:


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Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt

Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche


Structure of the Technological Processor

data base

START

technological

data

CAD-system

geometrical

data

FE-

program

input file

output/ result file

yes

OK?

END

no

Iterative Optimizer

PreprocessorCompiler for input file

PostprocessorEvaluation and representation

of the results



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Programming-layout of the TP

Parameter entry

Compiling and editing of

routines

procedures and auto sequences

Automatic modelling

FE-Program

MARC/MENTAT

Programming languages:

Visual Basic (VB)

Visual Basic for

Applications (VBA)


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Entry masks

Selection of the process variant

Input of process-parameters


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Entry masks

Input of tool parameters


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Entry masks

Input of workpiece parameters

Initial position as well as workpiece

length will be calculated automatically.This yields to minimized element

numbers.

A manual input is also possible.


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Special entry masks

FEA-specific

details

Standard-grid

coarse middle smooth


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Single stroke discretisation

Special entry masks


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these masks are provided for the advanced user

they normally are skipped

Storage of the results

Remark to the special entry masks

Reduction of the amount of data

(storage-saving).

Not for all increments a result file is

written.

Special entry masks


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Evaluation masks

Evaluation of the course of forces

0 10 20 30 40 50 60Weg [mm]

0

25000

50000

75000

100000

125000

150000

Frad[N]

0 10 20 30 40 50 60Weg [mm]

0

2500

5000

7500

10000

12500

15000

Fax[N]

T:\Rundkneten\Vorschub\180703\5\fort.25.


3D Simulation

Kraftverlauf beim Vorschubrundkneten


max. Radialkraft: 126.1 [kN]

max. Axialkraft: 7.1 [kN]

Drehwinkel pro Hub: 13.6 []Axialvorschub pro Hub: 0.03 [mm] Gittertyp: G2




ohne Dorn


Force progression(Feed swaging without mandrel)

max. radial force: 126,1 kN

max. axial force: 7,1 kN

Swaging Frequency: 30 HzAxial rate of feed: 0,164 m/min


Process Parameters

Angle of rotation per pass: 12Axial feed per pass: 0,09 mm


Increments per pass: 7Grid-type: G2


path [mm]

path [mm]

Choose the file to be evaluated X

Save as: X


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Evaluation masks

Evaluation of the course of wallthicknessChoose the file to be evaluated X

Course of wall thickness(Feed swaging with mandrel; D=18.5mm)




Process Parameters





Grid-type: G2

wa

llthickness[mm]

path [mm]

Save as: XFE-specific quantities


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Evaluation masks

Representation of parameters of forming technology

.


Equivalent von Mises Stress

Vorschubrundkneten ohne Dorn


Max. Main Stress


Axialvorschub pro Hub: 0.26 [mm] Gittertyp:G2





Feed swaging without mandrel




Process Parameters





Grid-type: G2


Save as: X

C i FEA ith/ ith t t h l i l


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Comparison FEA with/without technological processor

MSC.Marc

Mentat

MSC.Marc

MSC.Marc

Mentat

Subroutines

Conventional execution

FE-Knowledges required in all

steps

Technological processor

Input via Entry-

masks

MSC.Marc

Automated

evaluation via

Entry masks

Hardly no FE-

Knowledge required

Pre-

processing 5 min120 h

STARTSTART

250 h 60 hSimulation

END

Post-

processing10 min

5 hEND

Time need reduced considerably !

S


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Summary

Reduction of the development timeReduction of the development time

Improv

edmod

elling

R

educ

edcom

puting

time

SimulationSimulation

Improved

availabilityandadministration

oftheknowledgeoftheproc

ess

Knowledge baseKnowledge baseTechnological processorTechnological processor

Examination of the rotary swaging process with thehelp of 3D-FEA

Simplified use and integration of FEA in the process

planning


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Thank you for your attention!

Rathmann_4th ICFG Workshop

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