DEFORM-Preform Wizard Lab

3D PREFORM DESIGN LAB (USING PREFORM WIZARD)

1. Introduction to Preform Design

2. Initial Preform Design Scheme

3. Getting Started with the System

4. Defining model type and importing part geometry

5. Parting plane definition

6. Define Flash Model

7. Define Filtered Shape

8. Define Preform Shape

9. Prepare Preform Geometry

10. Generate Mesh for Preform Shape

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11. Saving the Designed Preform

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12. Overview of preform modification scheme

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13. Preform modification Procedures

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14. Loading the previous run results

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15. Check position

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DEFORM-2D Labs - September 1995

16. Analyze simulation results

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17. Smoothing Preform Modification Geometry

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18. Create Modified Preform Geometry

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19. Prepare Preform Geometry

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20. Generate Mesh

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21. Save Designed Preform and Continue

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DEFORM-Preform Wizard Lab

Summary:
In the forging process of complex 3D parts, multiple intermediate shapes must be
used to control metal flow and material distribution to ensure proper filling of the finisher
die. A systematic method to design an intermediate shape (known as a blocker or a
preform) is especially important for a successful outcome in the forging process. In the
conventional process design the quality of the blocker/preform design is highly dependent
TM
upon the designers experience. DEFORM -3D provides tools to minimize and ultimately
remove the experience dependency from the design process. In this document we briefly
discuss various stages of this design process using the functionality of the Preform wizard.
As the system is currently undergoing improvements and questions or suggestions related
to this functionality may be emailed to support@deform.com. For the illustration
purpose we use Preform design sequence for a typical automotive connecting cod.

1. Introduction to Preform Design

In forming process, an intermediate shape so called Preform or blocker is
necessary if final forged shape is complex. By using Preform shape, lower forming load,
uniform strain distribution, no die under filling and reduced die wear can be obtained by
introducing smooth metal flow. Conventional way of designing Preform shape is inefficient
and time consuming in that it requires many cross sections and the design will be done in 2
dimension so the designed cross sections need to be connected each other to make 3
TM
dimensional Preform shape. Preform Design module in DEFORM -3D is a special tool to
design initial Preform shape from final forged shape. In this process 3 dimensional CAD
model will be used as input and the designed 3 dimensional Preform shape is an output as
TM
well. The out put can be a STL file or DEFORM -3D Keyword format for the Preform.
This Preform data (STL form or keyword format) can then be loaded in regular pre
processor, to define the rest of the forming process conditions and material data to run the
simulation. After the simulation is complete, design modifications can also be carried out
using the features available in this module.

2. Initial Preform Design Scheme

For a given final part configuration, there are three steps to generate an
initial Preform shape. (Figure 1)
1. Digitizing process - The final part geometry is imported into the system as a
triangulated surface, in STL or other format. The digitizing procedure is first
performed to convert the triangulated surface into a point cloud array.
2. Filtering process - The resulting surface will be passed through a filtering procedure
to produce a smoothed shape. In the filtering procedure, the geometric domain will
be converted into a frequency domain by using a Fourier transformation. By using
the filtering function, high frequency regions (sharp corners, edges, or small
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DEFORM-Preform Wizard Lab

geometric details of a surface) will be removed. An inverse Fourier transformation

will then be applied to obtain a smoothed surface.
3. Trimming process - The trimming procedure is used to control the boundary shape
of a smoothed shape, so as to get a realistic initial Preform shape.

Digitizing

Filtering
Final forged shape
CAD model (STL)

Digitized geometry

Trimming

Designed Preform shape

Smoothed geometry

By filtering method

Figure 1. Preform design sequence

3. Getting Started with the System

From the DEFORM main menu, start the new problem (
). Choose Preform as
Problem Type from the problem setup menu. (Figure 2). Then select appropriate problem
directory, followed by problem name to enter the Preform wizard.

DEFORM-Preform Wizard Lab

Figure 2. Selecting the Preform wizard for new problem

When the procedure is entered for the first time, select the option Create a new
preform shape from the Start menu. (Figure 3)

Figure 3. Opting for new preform shape

DEFORM-Preform Wizard Lab

4. Defining model type and importing part geometry

As the basic shape of the part is symmetric we need to model the upper part only. In the
Define Model menu select the option Upper part only. Click on Next to select the part
geometry file Connecting_Rod_WorkPiece.STL and click Next to load it. Currently
Deform can accept the STL, Universal and native DEFORM formats.

Figure 4. Selecting the model type and loading part geometry

DEFORM-Preform Wizard Lab

5. Parting plane definition

After importing the geometry, next step is to define the parting plane. Here user can define
either planer or non planer surface. For planer parting surface definition user needs to specify
the z-coordinate location of the parting plane. Input z = 0, or pick the point on the geometry as
shown below. (Figure 5). Non-planar parting surface option requires additional parting surface
definition

Figure 5. Defining parting plane

Click Next to proceed. From the Digitize final shape menu, select Draft for
the digitizing option and click Next. Note that Normal and Fine options are
available if more accurate surface representation is desired. The system will now
create the digitized surface. In the subsequent Define Volume Ratio menu,
choose Define volume ratio with flash model (this is the only option available
now).

DEFORM-Preform Wizard Lab

6. Define Flash Model

In the Define Flash Model menu select the option Create target shape with flash. Enter 0.5
for flash thickness, 10.0 as flash width and click on Preview to check the flash model.

Figure 6. Defining flash model details

The system will automatically calculate and display the volume ratio between the preform
and the target part shape. Depending upon the part type this ratio typically represents
about 3%-5% additional volume in the preform. Click Next to proceed.

7. Define Filtered Shape

In the Define Filtered Shape menu, choose the option Create filtered shape with an alpha
value. Here value of Alpha can be used to adjust the preform surface smoothness, and
value for Scale can be used to control the height of the preform above the parting
surface. Default values for Alpha as 0.3 and Scale as 1.0 (same height as target shape
height) are reasonable for the current problem as a first design. User can change these
values and click on Preview to verify the same. (Figure 7). Click Next to continue.

DEFORM-Preform Wizard Lab

Figure 7. Defining filtered shape

8. Define Preform Shape

In Define Preform Shape menu, select the option Define from outer boundary. With
respect to the filtered shape, input the Distance from outer boundary as 5 and Draft
angle as 5 degrees. Distance specified here indicates how much of the filtered shape has
been trimmed to get the preform shape. Click on Preview to verify (Figure.7) the data
and Next to proceed.

DEFORM-Preform Wizard Lab

Figure 8. Defining Preform shape

9. Prepare Preform Geometry

In Prepare Preform Geometry menu, select the option Create a closed preform shape by
mirroring upper shape. This will reflect the surface geometry defined in the previous step,
and make the complete closed part, which is required for FEM mesh generation. (Figure 9)
Click Next to continue.

DEFORM-Preform Wizard Lab

Figure 9. Preparing Preform Geometry

10. Generate Mesh for Preform Shape

In the Generate Mesh for Preform Shapemenu, select the option Generate mesh and
specify the approximate number of elements to be generated for the Preform. (Figure 10)
Please note that depending upon the part complexity, user may need to specify sufficiently
large number of elements so that the material flow is well represented in the critical regions
of the die cavity for more accurate Preform design. Click on Next to continue

DEFORM-Preform Wizard Lab

Figure 10. Generating mesh for Preform

11. Saving the Designed Preform

After the mesh generation, generated mesh can be saved as a keyword file and STL output.
For subsequent design iterations save the wizard file also. (Figure 11)

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DEFORM-Preform Wizard Lab

Figure 11. Saving the Preform data for analysis

After saving the preform data in the keyword file the following details (to generate the
database in GUI_PRE) can be used to run the forging simulation.

Select the key word file (PREFORM.KEY) from the folder tree and open Preprocessor
Set the unit system to SI units.
Use the top die geometry Connecting_Rod_Top_Die.STL (from LABS folder)
Use the bottom die geometry Connecting_Rod_Bottom_Die.STL
Position the dies and work piece with 0.02mm interference and generate contact.
Constant shear friction of 0.08 between the mating parts.
Top die speed = 10 mm/sec, Step size = 0.01mm/step.
Stopping criteria is 0.5 mm (final flash thickness) distance between the dies.
Material for the work piece is 1045 steel (cold) from the library data.
Isothermal simulation mode, CG solver with direct iteration.

12. Overview of preform modification scheme

General considerations for an ideal preform are:

Complete die cavity filling (no under-fill)

Concurrent or near concurrent die filling in every sharp corner
No defects like folds, flow defects, etc.

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DEFORM-Preform Wizard Lab

Uniform flash (uniform volume distribution)

Reduced tool wear (by decreasing load and flow-by die features)

When the undesirable flow conditions occur, two questions are usually considered for
modification:

Where the initial preform should be modified?

How much volume should be added or removed at each modification point?

The suggested preform modification scheme is illustrated in Figure. 12.

DEFORM

TM

Simulation
Initial Preform
geometry

Simulation result

Updating

Preform

Modified Preform geometry

Desired result

Analyzing

Geometric changes
to preform

Figure 12. Overview of Preform Modification scheme

Reference:
Jin Yong Oh, Jae Bong Yang, Wei-Tsu Wu, Hugo Delgado, Finite Element Method Applied to 2D and
3D Forging Design Optimization, NUMIFORM 2004

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DEFORM-Preform Wizard Lab

13. Preform modification Procedures

After the initial deformation run with preform, we can now proceed to second iteration of
the preform design, based on the deformation behavior of the first trial. Select the .PWZ
file of the first run and open the Preform wizard from the main menu. Choose the option
Open with Keyword and wizard files from the Problem Loading menu. (Figure 13)
Now choose the option Modify Preform Shape from the Start menu.

Figure 13. Opening the previous problem files, and selecting the Modify options

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DEFORM-Preform Wizard Lab

14. Loading the previous run results

Once in the Preform wizard in the Setup tree select the option Import Simulation Result
and click Next to browse the database file and select the object and step number from
there. (Figure 14).

Figure 14. Opening the previous Preform design database.

15. Check position

In the Check Position user has an option to reposition the flash model compared to the
first design. For this example we choose not to change this part of the data. Click Next to
continue. (Figure 15).

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DEFORM-Preform Wizard Lab

Figure 15. Positioning the flash model.

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DEFORM-Preform Wizard Lab

16. Analyze simulation results

In the Analyze Simulation Result menu we can specify the tolerance value on the volume
and compute the die under fill from the previous deformation simulation. We can use
0.001 for this tolerance value and click on Calculate to compute the under fill values, and
display the regions of under fill. (Figure 16). Click Next to continue.

Figure 16. Analysis of simulation results for under fill.

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DEFORM-Preform Wizard Lab

17. Smoothing Preform Modification Geometry

Based on the die under fill observations, in the Smoothing Preform Modification
Geometry menu, we can modify the surface smoothing value Alpha and add more
material in the desired regions by specifying larger scale value. For this example use 0.65
for Alpha and 1.5 for Scale value. (Figure 17). Click Next to continue.

Figure 17. Smoothing Preform Modification Geometry.

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DEFORM-Preform Wizard Lab

18. Create Modified Preform Geometry

In the Create Modified Preform menu select the option Create modified preform and
specify a volume change limit as 7 %. Click Next to proceed. (Figure 18). Click Next
to create and continue. (click on Back to check on what is created). This step adds
material in the under fill regions based on the analysis results from step 16.

Figure 18. Creating modified preform geometry.

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DEFORM-Preform Wizard Lab

19. Prepare Preform Geometry

In the Prepare Preform Geometry menu select the option Create a closed preform shape
by mirroring upper shape (Figure 19). Click Next to create and continue. (click on
Back to check on what is created)

Figure 19. Prepare preform geometry

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DEFORM-Preform Wizard Lab

20. Generate Mesh

In the Generate Mesh for Preform Shape menu select the option Generate mesh (Figure
20) and specify 45000 elements and click Preview to check the mesh and Next to
generate and continue. Please note that for second and subsequent iterations finer mesh is
generally recommended.

Figure 20. Mesh generation for Preform shape

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DEFORM-Preform Wizard Lab

21. Save Designed Preform and Continue

Save Designed Preform menu gives options to save the Preform and continue. After this
point user needs to load appropriate die set in GUI pre and repeat step 11, indicated in this
document to complete the second design iteration. Repeat the steps 12-21 as needed to
complete the preform design.

Figure 21. Saving the Preform data for analysis

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