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Everything posted by Renga@MFRC

  1. Hello, I would like to export the residual stress results from a forming simulation in Hyperform to carry out a structural analysis of the formed part in OptiStruct. Could some one please share a tutorial based on this workflow? Thank you in advance. Regards,
  2. Hello Lutz, Was eager to know if this bug has been fixed? I would like to use negative values for design variables but I keep getting the message "initial value not included in values". Because of this, I am not able to go to the next step. Your response would be appreciated. Regards, Renga
  3. If you want to use symmetry, you don't have to model the full geometry as you have done. As I have indicated in my picture, please model only a sector of the cylinders (Lower die, work piece) and cone (upper die). Then you have to select the 2 planes which go along the height dimension of the work piece. The planes that you should chose on the work piece are numbered as 1 and 2 in the below picture. (Only work piece and lower die shown in this picture) Refer to AFDEX Manual in the installation folder for more details.
  4. Hello, I assume the cylinder in rose color denotes your work piece. Then you should model only a sector of the work piece and dies (for example 30, 45 or 60 deg) and then select the planes of symmetry like shown in the below picture. Regards, Renga
  5. Hello everyone, AFDEX MAT is the material identification module which is used for obtaining flow stress information from the load versus elongation data which is got from tensile/compression tests. Figure 1: Material identification using AFDEX MAT Figure 2: Fracture prediction in tensile test To know how this algorithm works, you can read this. Do get in touch with our technical support team (r.sekar@afdex.com) for further specific details. Cheers from AFDEX Support team!
  6. Hello everyone, Cross wedge rolling is a plastic deformation process carried out at elevated temperatures to exploit the advantage of lesser deformation forces. The initial work piece is mostly cylindrical in shape and is deformed into stepped parts by the tangential movement of dies around the work piece. The process boasts of high efficiency, ease of automation and equipment simplicity. The automotive industry is getting more creative regarding the application of cross wedge rolling. Below are some snapshots of a cross wedge rolling process simulation using AFDEX. Do get in touch with our technical support team (r.sekar@afdex.com) for further specific details. Cheers from AFDEX Support team!
  7. Hello everyone, Self-piercing riveting is a high-speed single-step technique for joining sheet material. Below is an example of the self-piercing riveting process simulation using AFDEX. The rivet and the two sheets were considered as work piece in the simulation and a binder force was applied on the sheets during the riveting. Get in touch with our technical support team (r.sekar@afdex.com) for further details. Cheers from AFDEX Support team.
  8. Dear Forum users, The AFDEX predictions of a chevron crack which occurs during the extrusion process is presented and the results are compared with experiments for validation. Cheers from Support Team !
  9. Hello Forum users, An automatic multi-stage precision cold forging process of a yoke was simulated with emphasis on springback phenomenon using an elastoplastic finite element method. The results are discussed below. Figure 1. Yoke to be studied (cold forging) Figure 2. Process design and simulation result of the 6-stage cold forging process Figure 3. Returning process of the punch in Stage 5 – Contours of nodal velocity shown in the picture Figure 4. Measurement of distances between measuring points at ears before and after the punch returning process It was observed that the AFDEX predictions deviated from the experiment values by 16% in this example. Cheers from AFDEX Support Team !
  10. Dear Forum users, Here is another example of 2D and 3D combined simulation in AFDEX. The above figure compares the AFDEX predictions with the experiments. This is an automatic four-stage cold forging process for a high-strength bolt. The metal flow lines can also be visualized. Cheers from AFDEX Support Team!
  11. Hello Vivian, Yes. It is possible to create a new material and use it for your simulation if you have the material properties. You would be needing the material module “AFDEX-MAT” for doing this. This module can be executed from the installation folder. In terms of input data, for defining a material, you should be having the plastic deformation information. This can be load vs. elongation data, engineering stress vs. engineering strain data or true stress vs. true strain data. You would also be asked to enter the diameter and gauge length of the specimen that you had used during the tensile/compression test. If this information is not available, you should be choosing the "Hollomon model" to define the material. But this topic is a separate post in itself. I hope I have answered your question. Cheers from AFDEX Support Team !
  12. You are welcome. Please do get in touch if you need more information.
  13. Hello dear forum visitors, AFDEX 3D can read AFDEX 2D results files either directly or by means of a simple connecting program, and thus 2D and 3D combined simulations can easily be carried out. Of course, the 2D results can be viewed by the 3D post-processor with more powerful graphics functions. Figure 1. shows the predictions of a five-stage precision cold forging process involving one piercing stage and a final three-dimensional stage, obtained by using the 2D and 3D combined simulation capability with minimum user intervention (i.e., with only an initial run and one connection run). Figure 1: 2D and 3D combined simulation - AFDEX It should be noted that this capability is especially efficient for fastener forming process simulation. The 2D and 3D combined simulation is strongly recommended for enhancing computational time, solution reliability, and engineering productivity when relatively few stages are three-dimensional. So it's time to use your resources smartly. Cheers from AFDEX Support team!
  14. Hello everyone, The figures below compare the AFDEX predictions and experiments of a bevel gear manufacturing process composed of an enclosed die forging stage and a consecutive sizing stage. As this is a representative process in near-net shape manufacturing, a precision simulation is required. Figure 1: Process 1 - Enclosed Die Forging Figure 2: Process 2 - Sizing Figure 3: Enclosed Die Forging - Comparison Figure 4: Sizing - Comparison Cheers from AFDEX Support Team!
  15. Damage models play a decisive role in predicting the fracture phenomena that occur during metal forming or material testing. They may be classified into many categories based on energy, pore-growth micromechanics, porous material and continuum-damage mechanics. AFDEX supports the following damage models as shown in Figure 1 in the current version. 1. Cockroft & Latham Normalized 2. McClintock 3. Brozzo, Deluca & Rendina 4. Oyane, Okimoto & Shima 5. Rice & Tracey 6. Freundenthal Figure 1: Damage models in AFDEX For predicting the crack propagation, AFDEX uses an improved node-splitting technique in the quadrilateral mesh system. Figure 2 shows the history of the fracture formation made using the Brozzo et. Al damage model. It can be observed that the early crack propagates horizontally up to two thirds of the radius of the material. The crack growth is then finalized in the inclined direction. Figure 2: History of fracture formation by the Brozzo et al. damage model A detailed view of the fracture surfaces predicted using different damage models is presented in Figure 3. Figure 3: Detailed view of Fracture surfaces All the major damage models predicted acceptable solutions in terms of the slope of the tensile load drop in the fracture region. It can be observed from Figure 4 that the Freudenthal damage model came closest to the experiments. Figure 4: Load vs. Elongation curve based comparison For more details, reading the literature in the link below is recommended. http://msjoun.gnu.ac.kr/pub/paper/2014/Evaluation of Damage.pdf Cheers from AFDEX Support Team !
  16. Hello Vivi, Thanks for your question. If you have used the "Symmetry" option, don't worry. AFDEX will automatically calculate the results for the whole model. Just make sure that you define the planes of symmetry correctly. So let's say you have a model like this below. You will be tempted to utilize the rotational symmetry right? Why not? Define the planes of symmetry by double clicking "Symm_Plane(0)" command in the project window and select the respective planes. The number in the brackets represent the number of defined symmetry planes. And when you have completed the simulation, you can visualize the whole model using the "Mirror" command. The picture given below would give you more clarity. The region "Analyzed" represents the 22.5 degree sector of the whole model used for simulation. Hope you got the point. A quick one-picture tutorial for using the "Symmetry" command in AFDEX. Cheers from AFDEX Support Team!
  17. Hello Mr. Vinod, There seems to be a lot of demand from our users about the inclusion of heat treatment modules in AFDEX. Our development team has been working on it for some time and it can be expected to be released for commercial usage very soon. I will definitely let you know if we have finalized on the date of release. Cheers from Support Team!
  18. Hello Mr.Vinod, Thank you very much for your interest. Extrusion processes could of course be modeled using AFDEX. You can see an animation of a forward extrusion process using the elastoplastic deformation type in AFDEX here. When a manufacturing process is selected in the "Process Information" dialog box, the changes come into effect at the back end of the software. This can be checked by looking at the second line of the SCF file. These files would be automatically created in the folder where the simulation is saved. Please refer File Types in AFDEX in case you would like to know the details that go into each of the supporting files of a simulation. The second parameter in the second line of a scf file usually denotes the manufacturing process. Ex: 2 - Rolling; 3 - Forging; 4 - Drawing; 5 - Extrusion, and so on.... So in this case, as we are executing a extrusion simulation, the second line of the SCF file would look like 70 5 2 1 I have sent a step by step tutorial for a forward extrusion process simulation to your email. Kindly let me know if you need more information. Cheers from Support Team!
  19. Hello dear Forum users, Below is an interesting simulation result of our AFDEX logo using AFDEX. Cheers from Support team.
  20. Hi, Yes of course, you can manually edit the input files (scf and sif) and control the simulation. But this would be rarely needed as the GUI has been designed in such a way that almost all processes could be defined there itself. There is a special program called AFDEX Input Converter (AFDIC) which helps you edit the SCF and SIF files in case of advance forging processes like ring rolling, radial forging etc. But as I mentioned before, you would rarely have to manually edit these files as you can do everything you want either using the GUI or the AFDEX Input converter in case of advanced processes. Cheers.
  21. Hello Everyone, We saw different file types and their meaning in previous posts and the usage of the batch file to execute a simulation. As promised earlier, here is a post that demonstrates how to execute multiple simulations simultaneously. Step 1: Save the simulation files in the same folder. Do not run them Step 2: "Edit" all the ".bat" files as shown in the figure. Step 3: The highlighted first line in every batch file is very important. These lines need to be pasted on a new batch file for simultaneous execution. Step 4: Make a copy of one of the existing ".bat" files like shown in the figure. Step 5: Enter the lines from batch files into the new notepad as shown in the picture. Step 6: Double Click the new batch file to execute the simulations. Let us know what you think and feel free to ask questions if you have any. Cheers from AFDEX Support Team!
  22. Hello everyone, Let’s assume you have the process design and all the relevant parameters to simulate. So you open a new project in AFDEX, import geometry and define all other simulation factors. This creates .prj, .scf, .sif, .slf and .bat files. Don’t get worried about the new terms. Just have a look at my earlier post (File Types in AFDEX) to get yourselves acquainted. Like any Job Control Language, batch files (.bat) give us the freedom to write our own script so that we can automate the task of running simulations. So after the process definition is over in AFDEX, you can also double click and execute the .bat file to run the simulation. This trick will be very useful if you must execute multiple simulations simultaneously. Please keep following our forum. The next post would probably have an example showing the usage of .bat file to execute multiple simulations in this manner. Following is an example of a effective strain contour from a plate forging simulation executed from the .bat file. Please feel free to ask if you have any questions. Cheers! AFDEX Support Team
  23. Hey Vivian, Thanks for your interest. Yes, AFDEX can simulate many advanced metal forming processes. Open die forging processes like radial forging can also be simulated. Following are the different types of simulation that have been carried out using AFDEX. You can probably use the search function to find if your process is in the list. Closed die forging Chipless forming Multi body forming simulation Roll forging Rotary forging Self rivetting simulaiton Hot and cold profile ring rolling Heat sink forging simulation Material push out extrusion Radial forging Cross Wedge rolling Extrusion of Multi body with back pressing Radial forging of stepped, prismatic or square bar Material-Material Contact(Self-Contact) treatment Beam Bending Roll piercing Flexible thermal boundary condition treatment 2d rolling simulation Roll pipe elongating Die Structural analysis Shape rolling Mannesmann effect Fine blanking simulation Roll forming simulation Swaging Superplastic forming Machining process simulaiton Radial ring forging Plate forging Springback by elastoplastic and rigid plastic FEM Tube drawing with backpressing Square Cup Deep drawing Drawing - Elastoplastic FEM Thread rolling Air pocketing phenomenon analysis Forward extrusion Chevron defect in extrusion Hot plate forging Porthole Extrusion Six stage drawing Powder forging Thick Plate piercing Cogging, Cylinder compression, upsetting Simple Non isothermal analysis Large Bearing manufacturing simulation Please do follow our posts, I will be posting interesting simulation examples on some of the advance manufacturing processes. Bye, Renga.
  24. Hello everyone, The list of values of state variables like effective stress or effective strain from a metal forming simulation using AFDEX can be easily obtained from the results folder. 1.Navigate to the simulation results folder 2.Open the “element_value.txt” file to view the effective strain and damage values of elements 3.Open the “”node_value.txt” file to view the effective stress and the principal stress values Let us know what you think and feel free to ask questions if you have any. Cheers from AFDEX Support Team!
  25. Hello people, This post is about using the "Probe" command in AFDEX to directly pick the nodes of interest from the screen and know the values of state variables like Effective Stress, Effective Strain etc. 1.Open the simulation result file (Format: .a2dsrf for 2D and .a3dsrf for 3D, refer AFDEX File types for details) and select the parameter whose value needs to be probed from the post-processor window. In this example, effective stress is selected. 2. Click the "Probe" command from the tool window and select the node of interest. The probed value is displayed on the lower bottom of the screen. Let us know what you think and feel free to ask questions if you have any. Cheers from AFDEX Support Team!
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