Forming Modules
Ring Rolling has been one of the most computationally demanding applications in metal
forming simulation. Traditional process simulation codes require days, weeks or months
to analyze typical jobs. Even with extremely fast hardware, the 'brute force' methods
employed by such codes are impractical.
Specialized ring rolling capabilities are
available in DEFORM-RR and the Ring
Rolling Module. The application-specific
preprocessor streamlines the model setup
procedure. The FEM engine is extremely
efficient, as it was specifically designed
for ring rolling. Simulations that previously
took weeks now run in hours to days.
This 'state of the art' system utilizes an
ALE solver with automated time stepping.
The model uses brick (8 node) elements
and supports fully automatic adaptive
remeshing. The updating and contact algorithms are optimized for ring rolling. The result
is an accurate solution, without artificial constraints on the rotation axis.
DEFORM is the first code to deliver a ring rolling program capable of running on practical
hardware in reasonable times. Test cases have been run with 15-20,000 brick elements
running 25 to 75 revolutions in approximately an hour per revolution, on a single CPU PC!
Cogging is an open die forging process used to convert a cast ingot into forged billet.
A typical process involves hundreds of local reductions, along the length of the billet,
spanning several heats. The workpiece is typically rotated between or during passes.
The ingot cross section is reduced as it changes shape to a round, hexagon or octagon.
This thermo-mechanical processing refines the coarse ingot grain structure to
homogenized, fine grained, recrystallized billet microstructure.
Process simulation can involve hundreds or thousands of deformation and heat transfer
models. While possible, a manual setup is tedious and impractical. To address this
challenge, SFTC developed and optimized the Cogging Module to enable a user to set
up cogging simulations in minutes. Standard billet, die and manipulator geometries are
included. Process parameters include number of heats, pass schedule, ingot rotation,
bite size and the time between bites
and passes. A simulation preview
is provided to identify potential input
errors prior to FEM calculations.
This enables the user to run cogging
simulations without user intervention.
This module is extensively used by
leading material suppliers to analyze
the ingot conversion process.
Simulation provides critical
information about shape, strain,
temperature, defects and more.
This is used to determine optimum
process parameters, resulting in
improved material yield and fewer
quality problems.
Ring Rolling
• Ring Rolling simulation is available
as a module that runs with
DEFORM-3D.
• DEFORM-RR is a stand-alone
version of the Ring Rolling program.
• The current isothermal implementa-
tion supports a workpiece, drive roll
and mandrel.
Cogging
• The Cogging module runs in
conjunction with DEFORM-3D.
• Cogging models can involve
hundreds of operations, thus storage
requirements may be higher than
most other applications.
