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Basil Baby

Analysis of a forging die

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We are trying to analyze the failure of a forging die of a flange. The stationary die got cracked during the operation. So we are trying to find out a solution for the same. We are planning to use Altair HyperWorks to simulate this event.
 
Details of corresponding die:-
 
Die Material - DIN 2714
Hammer - 16 tonnes(42000 kgf)
 
Flange material - Titanium- 6Al-4V
Flange temperature - 870-950°c
 
Can you Please suggest the commonly used method used for Modelling and Analysis.
Thank You.

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Guest

Hi Basil,

Is it failing at the first time of use? Or is it a failure after many cycles (more like fatigue)?.

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1 hour ago, George P Johnson said:

Hi Basil,

 

Is it failing at the first time of use? Or is it a failure after many cycles (more like fatigue)?.

Yes, it cracked after the first hit.

let me know what type of meshing and analysis should I do?????

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Guest

Hi Basil,

Crack propagation can be simulated in RADIOSS. We have a similar example file in Help, Ruptured Plate and also a tutorial is available shown crack propagation which can be accessed at: https://altairuniversity.com/conceptual-design-of-a-3-wheeler-motorbike/conceptual-design-of-a-3-wheeler-motorbike-stone-impact-simulation/

Meanwhile I will try to get some information specific to this project.

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But in our case the work piece which is hitting the die , deforms to the flange shape and then the impact load is distributed to die. so in this case, the  normal impact load may not be applicable directly to the die, since the force is first transmitted to the work piece and then to the die.

so how can we solve this ?????????

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Guest

Hi Basil,

Prior to failure model set up you need to model the forming simulation for this set up in HyperForm. Normally we model the die as rigid in HyperForm but in this case keep it as deformable.

Now take this model setup into RADIOSS and for the die material get all the failure parameters so that we can use /FAIL/JOHNSON card and can simulate this in RADIOSS.

 

 

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Guest

Hi Basil,

In Help you will get many tutorials on HyperForm. Also there are some video tutorials available in YouTube.
 

hf.PNG

 

 

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Guest

Hi,

Please go through RD-E: 2600 Ruptured Plate in Example which shows modelling failure in RADIOSS and also go through RD-E: 4400 Blow Molding with AMS.

For the above mentioned examples, model files are available in your installation directory (<install_directory>/demos/hwsolvers/radioss/26_Ruptured_plate_____). please import them in HyperMesh and review the model.

 

For basic RADIOSS tutorials  please go through the tutorials available in Help. Also you can refer https://www.youtube.com/watch?v=CxM52wP3_ew&list=PLQ7KUGFuVz4u5y3SvIEIU07427-gATaG6 which is a webinar on HyperMesh-RADIOSS interface.

 

Also go through https://www.youtube.com/watch?v=aDeNhQFvqjE&t=8s which shows setting up a simple impact analysis in RADIOSS.

 

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Guest

Hi Basil,

The model setup will be somewhat like this (Check the model file attached).

Provide the appropriate material for the components and the failure card (as in the example above) and try running.

ASSEMBLED_MODEL.hm

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