Numerical Simulation in Bulk Forming Process: Journal For Technology of Plasticity, Vol. 32 (2007), Number 1-2
Numerical Simulation in Bulk Forming Process: Journal For Technology of Plasticity, Vol. 32 (2007), Number 1-2
Numerical Simulation in Bulk Forming Process: Journal For Technology of Plasticity, Vol. 32 (2007), Number 1-2
=
=
0 12 12
0 12 12
p p z
p p r
z z u
r r u
(1)
Using displacements point u
r12
and u
z12
, partial displacement statements per radius and height
are calculated: cu
r
/cr, cu
r
/cz, cu
z
/cz and cu
z
/cr. Based on these statements, components of
small strains may be determined [6]. Using relations of relative and logarithmic strains (2)
logarithmic strain values are obtained to be compared to the values of numerical FEM
simulation.
) 1 ln( c + = (2)
Effective logarithmic strain values are given in the form of three-dimensional diagram in Fig. 7.
-10
0
10
20
30
-10
0
10
20
30
0
0.5
1
1.5
2
Radius r [mm]
NUMERICAL EXPERIMENT FOR PROCESS CONTINUTY
Height z [mm]
E
f
f
e
c
t
iv
e
lo
g
a
r
it
h
m
d
e
f
o
r
m
a
t
io
n
|
e
=
=
0 10 10
0 10 10
p p z
p p r
z z u
r r u
(3)
Displacement increment is:
Journal for Technology of Plasticity, Vol. 32 (2007), Number 1-2
52
A = = = A
A = = = A
z z z u u u
r r r u u u
p p z z z
p p r r r
10 12 10 12
10 12 10 12
(4)
Further, displacement velocities in node points of the deformed network are determined (phase 12)
where partial displacement speeds per radius cv
r
/cr, cv
z
/cr and height cv
z
/cz, cv
r
/cz, are
determined, based on which strain rates are obtained. In this way we come to radial, axial and
angular deformation velocity components, whereas rim velocity is determined as a ratio between
radial displacement velocity and radius.
Effective strain rate values are given in the form of three-dimensional diagram in Fig. 8.
Stress is determined by using the method of higher theory of plasticity. The method is based on
obtaining axial stress component
z
, by solving the basic equation of plasticity [6]. Input data are:
node point coordinates at the beginning r
p0
and z
p0
and at the end of the process r
p12
and z
p12
,
hardening curve parameters c and n, as well as the results out of deformation
r
,
z
,
u
,
rz
and
e
and kinematic analyses
r
c ,
z
c ,
u
c ,
rz
and
e
c .
Effective stress values are given in the form of three dimensional diagrams on Fig. 9.
-10
0
10
20
30
-10
0
10
20
30
0
0.5
1
1.5
Radius r [mm]
NUMERICAL EXPERIMENT FOR PROCESS CONTINUITY
Height z [mm]
E
f
f
e
c
t
i
v
e
d
e
f
.
s
p
e
e
d
c
e
0
10
20
30
0
5
10
15
20
25
2.6
2.8
3
3.2
3.4
Radius r [mm]
NUMERICAL EXPERIMENT FOR PROCESS CONTINUITY
Height z [mm]
E
f
f
e
c
t
iv
e
s
t
r
e
s
s
o
e
Figure 8 - Effective strain rate ] [
1
s
e
c Figure 9 - Effective stress
e
[daN/mm
2
]
3.2. Numerical experiment per phases
With numerical experiment per phases, displacements per phases are determined first, after that
final value of strain, strain rate and stress are obtained by known procedures and methods. Based
on the obtained node point coordinates per phases, data are processed by a programme made
within a programme language MATLAB (v. 7.0). Input data are: node point coordinates at the
beginning r
p0
and z
p0
and per phases: r
pi
and z
pi
, 12 ,..., 2 , 1 = i . Point displacements are expressed
by.
=
=
1
1
pi pi zi
pi pi ri
z z u
r r u
12 ,..., 2 , 1 = i (5)
Journal for Technology of Plasticity, Vol. 32 (2007), Number 1-2
53
Where logarithmic strain are obtained
ri
,
zi
,
i u
,
rzi
and
ei
, 12 ,..., 2 , 1 = i at the end of
each phase of bulk forming.
Logarithmic strain values in 12
th
phase (at the end of bulk deformation process) are calculated by
(6).
_
=
=
12
1 i
ri r
,
_
=
=
12
1 i
zi z
,
_
=
=
12
1 i
i u u
,
_
=
=
12
1 i
rzi rz
i
_
=
=
12
1 i
ei e
(6)
Effective logarithmic strain values obtained per phases are given in the form of a three-
dimensional diagram in Fig. 10.
-10
0
10
20
30
-10
0
10
20
30
0
0.5
1
1.5
2
2.5
Radius r [mm]
NUMERICAL EXPERIMENT PER PHASES
Height z [mm]
E
f
f
e
c
t
i
v
e
l
o
g
a
r
it
h
m
d
e
f
o
r
m
a
t
io
n
|
e
= e (7)
For adopted deformation velocity v=2 [mm/s], in 12
th
phase for time increment dt=0.1, relative
strain rates are determined.
Effective strain rate values in the observed points of meridial working-piece cross-section are
given in the form of a three-dimensional diagram in Fig. 11.
Stress is determined by using the method of high plasticity. Input data are: node point coordinates
at the beginning r
p0
and z
p0
and at the end of deformation process r
p12
and z
p12
, hardening curve
parameters c and n, as well as the results obtained by deformation
r
,
z
,
u
,
rz
and
e
and
kinematic
r
c ,
z
c ,
u
c ,
rz
and
e
c analyses.
Effective stress values are given in the form of a three-dimensional diagram in Fig. 12.
Journal for Technology of Plasticity, Vol. 32 (2007), Number 1-2
54
-10
0
10
20
30
-10
0
10
20
30
0
1
2
3
4
Radius r [mm]
NUMERICAL. EXPERIMENT PER PHASES
Haight z [mm]
E
f
f
e
c
t
iv
e
d
e
f
.
s
p
e
e
d
c
e
0
10
20
30
0
10
20
30
2.6
2.8
3
3.2
3.4
3.6
Radius r [mm]
NUMERICAL EXPERIMENT PER PHASES
Height z [mm]
E
f
f
e
c
t
iv
e
s
t
r
e
s
s
o
e
Figure 11 - Effective strain rate ] [
1
s
e
c Figure 12 - Effective stress
e
[daN/mm
2
]
3.3. DEFORM results
For concave die shape deformation change, speed and stress values in each phase of the observed
process for the adopted node points are obtained directly out of DEFORM-2D software package.
Values of these components at the end of deform process, effective logarithmic strains, effective
strain rates and effective stress are given in Fig. 13. to Fig. 15.
-10
0
10
20
30
-10
0
10
20
30
0
1
2
3
4
Radius r [mm]
DEFORM RESULTS
Height z [mm]
E
f
f
e
c
t
iv
e
lo
g
a
r
it
h
m
d
e
f
o
r
m
a
t
io
n
|
e
-10
0
10
20
30
-10
0
10
20
30
0
1
2
3
4
5
6
Radius r [mm]
DEFORM RESULTS
Height z [mm]
E
f
f
e
c
t
iv
e
lo
g
.
s
p
e
e
d
c
e
Fig. 13. DEFORM effective logarithm strain
e
Figure 14 - DEFORM effective strain rate
] [
1
s
e
c
Journal for Technology of Plasticity, Vol. 32 (2007), Number 1-2
55
-10
0
10
20
30
-10
0
10
20
30
0.5
1
1.5
2
2.5
3
3.5
Radius r [mm]
DEFORM RESULTS
Height z [mm]
E
f
f
e
c
t
iv
e
s
t
r
e
s
s
o
e
Figure 15 - DEFORM effective stress
e
[daN/mm
2
]
4. CONCLUSIONS
Numerical simulations of bulk deformation process have been carried out in the current paper, by
using finite element method, as well as the programmes based on plasticity theory. The numerical
experiments carried out simulate the conditions of a real object. Stress-strain deformation state
parameters of a working-piece in open dies of axi-symmetrical elements have been determined.
Numerical simulation is performed for a stepped concave die shape and it consists of three phases:
numerical experiment for process, numerical experiment per phases and DEFORM results.
REFERENCES
[1] auevi M.: Theory of Plastic Metal-Working. Svjetlost, Sarajevo, 1979.
[2] DEFORM Mannual - SFTC.
[3] Janji M., Vukevi M., Domazetovi V.: Application of Discretization Method in
Deformation Analysis of odpreska. XXIV JUPITER Conference, Zlatibor, 1998.
[4] Janji M., Domazetovi V., Savievi S., Vukevi M.: Determining hardening curves and
their choice in numerical simulations. XXXI JUPITER Conference, Zlatibor, 2005.
[5] Janji M.: Investigation strain-stress parameters in bulk-forming processes - Doctor's thesis,
Faculty of Mechanical Engineering, Podgorica, 2005.
[6] Musafija B.: Applied Plasticity Theory, University in Sarajevo, Sarajevo, 1973.
[7] Musafija B.: Plastic deformation Metal Working. Svjetlost, Sarajevo, 1972.
[8] Plancak M.: Strain-stress state in processes of cold steel extrusion. Faculty of Engineering
Sciences, Novi Sad, 1984.
[9] Vukevi M., Janji M., Domazetovi V.: Influence of geometrical parameters at deforming
axi-symmetrical samples in open-dies. XXVI JUPITER Conference, Beograd, 2000.
[10] ibali N.: Modeling of bulk metal forming processes using methods of physical
discretization and numerical simulation - Master thesis, Faculty of mechanical Enginering,
Podgorica, 2007.
Journal for Technology of Plasticity, Vol. 32 (2007), Number 1-2
56
NUMERIKE SIMULACIJE KOD PROCESA
ZAPREMINSKOG DEFORMISANJA
Vukevi Milan, Janji Mileta, ibali Nikola
Univerzitet Crne Gore, Mainski fakultet, Podgorica, Crna Gora
REZIME
U radu je data simulacija naponsko deformacionog stanja zapreminskog deformisanja u
otvorenim kalupima, po procedurama koje predstavljaju odreene metode. U numerikim
simulacijama mogue je diskretizacijom procesa po fazama deformisanja, odrediti deformacione
parametre u svim fazama. Komponente tenzora logaritamskih deformacija odreuju se na osnovu
pomjeranja taaka meridijalnog presjeka po fazama deformisanja, a ukupna deformacija se
izraunava kao suma deformacija dobijenih u fazama deformisanja. Dok se komponente tenzora
napona odreuju metodom visioplastinost.
Za numeriku simulaciju koristi se softverski paket DEFORM-2D, koji je namijenjen za analizu
ravanskih i osnosimetrinih deformisanja. Usvojen je stepenasto konkavni oblik kalupa, dimenzije
pripremka i raspored vornih taaka ija se pomjeranja prate tokom procesa deformisanja.
Numerika simulacija se sastoji iz tri etape:
U prvoj etapi se izvodi numeriki eksperiment gdje se za usvojene koordinate taaka u
nedeformisanom stanju dobijaju pomjeranja taaka na kraju procesa deformisanja. Na osnovu
ovih podataka o pomjeranju taaka odreeni su parametri naponsko deformacionog stanja. Ovaj
numeriki eksperiment se odnosi na kontinuitet procesa.
Druga etapa se odnosi na numeriki eksperiment, koji se realizuje za iste poetne uslove, ali se
proces zapreminskog deformisanja posmatra u fazama deformisanja i u svakoj fazi se posebno
odreuju naponsko deformacioni parametri, na osnovu kojih se dobijaju parametri na kraju
procesa deformisanja.
Trea etapa se odnosi na parametre naponsko deformacionog stanja koje DEFORM-2D
odereuje, a odnose se na iste poetne uslove.