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the button and select DEFORM-2D from the menu. The DEFORM-2D MAIN window
will appear, as shown below.
Create a new problem by either selecting File New Problem or by clicking the New Problem
icon. The PROBLEM SETUP window will appear. Accept the default setting of opening a
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Click to define the location of the new problem Under DEFORM Problem
directory.
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In the field for Problem Name, call the problem Mesh and click .
The DEFORM-2D Pre-processor will open. The Pre-processor is divided into several distinct
sections - namely the DISPLAY window, the Object Tree and Object Data. There is also a row
of icons along the top of the screen. These icons will be described as they are encountered in the
labs. The most important of the icons are the ones located at the top right. Due to their
importance, a brief description of each is given:
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Object Tree
Display window
Object Data
Click on the icon to open the SIMULATION CONTROL window. Change the Simulation
Title to Mesh. Make sure that the Units are set to English, Deformation is activated (has a
checkmark next to it), and Geometry is set to Axisymmetric. Click the button
when finished.
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Add an object to the problem by clicking the Insert object icon that is under the Object Tree.
Change the Object Name from Object 1 to Billet and then click the button. Set the
Object Type to Plastic.
Click and then click the Edit tab. A blank table will appear. Enter the following
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You should now see the geometry in the DISPLAY window. Click the to see if
there are any problems with the geometry.
Use the default checking parameters and click . A message saying "Geometry is
legal" will appear.
Functions that manipulate the DISPLAY window (such as Pan, Zoom, Magnify, and Rotate) can
be activated using icons at the top of the Pre-processor window. These functions also have easy
keyboard/mouse combination hotkeys that allow the user to quickly perform these functions
without any excessive button clicking. Once you have read about these functions, feel free to use
them to manipulate the view of the Billet in the DISPLAY window.
Display Icons
Select This is the default display mode and is used to select and
get information about nodes and element faces. This is
also the mode used when measuring.
View mesh only All objects are shown unshaded with a mesh.
View shaded mesh All objects are shown shaded with a mesh.
View surface patch Only the feature lines of the objects are shown
If you are not continuing on to Lab 2, you can exit DEFORM-2D by selecting either File Quit
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2. GEOMETRY INPUT - IGES FILES
the button and select DEFORM-2D from the menu. The DEFORM-2D MAIN window
will appear.
Create a new problem by clicking the icon. Accept the default setting of opening a new
In the field for Problem Name, call the problem Spike and click . The DEFORM-
2D Pre-processor will open.
Click on the icon to open the SIMULATION CONTROL window. Change the Simulation
Title to Spike Forging. Make sure that the Units are set to English, Deformation is activated
2.3.1. Object 1
Change the Object Name to Billet and set the Object Type to Plastic. The geometry for this
billet is located in an .IGS file. Click the button and then click .
All geometry files are located in the DEFORM2D\V*_*\Labs directory (where V*_* is the
currently installed version such as V8_0). Switch to this directory and import Spike_Billet.IGS
by highlighting it and then clicking . The imported geometry should appear in the
The points defining this imported geometry can be viewed/edited by clicking the Edit tab. When
.IGS files are loaded, the data gets imported into DEFORM in Line-Arc format, which defines
the geometry in terms of lines and arcs. To view the XYR format of the geometry, click the
XYR Geo Format button.
then the button. This not only fixes any problems with the geometry but also
corrects the orientation of the geometry if needed. Notice how checking this geometry changed
the orientation from clockwise to counter-clockwise, which is correct.
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2.3.2. Object 2
Highlight Object 2 in the Object Tree, click the button and change the Object Name to
Top Die. Click the button and then the file Spike_TopDie.IGS.
2.3.3. Object 3
Highlight Object 3 in the Object Tree, click the button and change the Object Name to
Bottom Die. Click the button and then the file Spike_BottomDie.IGS.
Save your data to a keyword file by clicking the Save icon. The data will be saved in the file
Spike.KEY.
If you are not continuing on to Lab 3, you can exit DEFORM-2D by clicking the button in
the MAIN window. When asked whether you want to quit, click .
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3. GEOMETRY INPUT - GEOMETRY CORRECTION
the button and select DEFORM-2D from the menu. The DEFORM-2D MAIN window
will appear.
Create a new problem by clicking the icon. Accept the default setting of opening a new
In the field for Problem Name, call the problem Junk and click . The DEFORM-
2D Pre-processor will open.
Click on the icon to open the SIMULATION CONTROL window. Change the Simulation
Title to Junk. Make sure that the Units are set to English, Deformation is activated and
Use the icon to add an object to the Object Tree. Change the Object Name to Billet and set
the Object Type to Plastic. Click and then click the Edit tab. A blank table will
appear. Enter the following XYR coordinates in the table and then click on the
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Using the Magnify icon, zoom in on the intersection between the two arcs. You can see that
the endpoints of the two arcs do not meet correctly.
Click the button and then . The message "Geometry has been
corrected" should pop up.
The default correction settings worked well for this geometry, creating a small line between the
two arcs.
Save your data to a keyword file by clicking the Save icon. The data will be saved in the file
Junk.KEY.
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Problem Summary:
The intent of the lab is to show the user how to import an IGES file geometry into
DEFORMTM and how to define a mesh for the geometry. There are two different
methods for defining the mesh of the object, system defined and user defined. Two
examples of each type are shown below in the example of a cross-section of a ring.
Notice the differences between Figures 4.1 and 4.2.
Figure 4.2:User Defined Defintion (Note the greater density at the object
boundary).
DEFORM-HT Labs
Checklist
1. User should be in RING directory
2. Named Problem ID RING
3. Entered the Pre-Processor
We need to define the workpiece for the simulation. Click on the Objects button
in the CONTROL window. The OBJECTS window will appear. In the
OBJECTS window the user can specify any data that applies to the activated
object. Object #1 is created by default so there is no need to create a new object.
Change the Object Name of object 1 to RING, and change the Object Type to
ELA-PLA (elasto-plastic). Now click on the Geometry button to define the
geometry of the selected object. The GEOMETRY window will appear with a
blank table. You will be reading the geometry in from an IGES file so click on
the Load IGES File button in the GEOMETRY window. The IGES FILE
SELECTION window will appear. Locate the IGES file RING.IGS under the
Files listing and double click the cursor on the filename. Now click on the Ok
button to read in the IGES file. The IGES FILE INPUT window will appear.
This contains a listing of information on the IGES file. The default settings
should be fine, so click on the Ok button. The Imported IGES geometry will
now appear in the DISPLAY window and the IGES window will appear listing
the number of curves, entities and points. Click on any line of the geometry.
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The object should change colors from white to yellow. Click on the Ok button in
the IGES TRANSLATOR window to import the selected curve. You will be
prompted whether you want to check the geometry of the imported object, click
on Yes. A window stating that the geometry is legal will appear, click on the Ok
button. The table in the GEOMETRY window should now contain a list of
points making up the geometry.
Important Note:
By looking at the direction of the lines of the disk, one can see that the lines
follow a clockwise direction. It is critical for the user to always make sure
that the geometrys used are counterclockwise in direction. DEFORMTM
uses the orientation of the lines to determine the outside and the inside of
objects. By defining the DISK as counterclockwise, DEFORMTM
understands the object to be filled with material and the outside to be empty
space. In the case where the user was to have clockwise geometry, clicking
on the Reverse Geometry Icon can reverse it. Improper orientation is often
the problem when the mesh generator is incapable of meshing an object or
when the user has a problem positioning the geometry by an interference
method. It should be noted that the check geometry feature doesnt check for
correct orientation.
Reverse the Geometry by clicking the Reverse Geometry Icon. Click on the Ok
button in the GEOMETRY window. The DISPLAY window should now display
the geometry you have created, a hollow disk.
Checklist
1. Titled Object #1 RING
2. Set RING type to Ela-Pla (elasto-plastic)
3. Loaded RING.IGS
4. Reversed geometry of RING
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The selected object will appear highlighted in red in the Display window. Set
the Number of Mesh Elements (MGNELM) to 600 elements. Now set the
Maximum Size Ratio (MGSIZR) to 1. This action will create a uniform the
mesh.
Now click on the Generate Mesh button to generate the mesh. To create a new
mesh, just change the mesh parameters and click on the generate mesh button.
Try this by setting the Number of Mesh Elements to 200, and click on the
Generate Mesh button. A new mesh should appear in the DISPLAY window.
You may continue to change the Number of Mesh Elements, Maximum Size
Ratio, and Number of Thickness Elements until you feel accustomed to these
features. It is important to note that all the information on the old mesh is
initialized. Click on the Ok button when you are finished.
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Checklist
1. Generated a system defined mesh on Object #1 with 200 elements
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Checklist
1. Generated user defined mesh as shown in Figure 4.4
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1. Locate the Simulation Title text box and title the simulation as Ring.
2. Change the Operation Name to Heating.
3. Set the Units to SI.
4. Note that the Object Geometry is set to Axisymmetric.
5. Set the Heat Transfer to Yes.
Click on the Stopping Step button when you are finished with the above tasks.
In the STOPPING STEP window,
Click Ok in the STOPPING and STEP CONTROLS window and then click Ok
in the SIMULATION CONTROLS window.
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To load the elastic and thermal data for this simulation, go to the menu bar at the
top of the control panel and select the File option. Under the Keyword option,
Load a file named STEEL_S.KEY. This file contains the elastic and thermal
properties of generic steel in SI units. In the CONTROLS window, click on the
Material Properties Icon (Figure 5.2). The elastic properties that were loaded
in the Pre-Processor are shown, Youngs Modulus, Poissons Ratio and Thermal
expansion. Note that the coefficient of thermal expansion is
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zero, thus there will not be a volume change upon heating. In order to make this
a coupled problem (i.e. deformation and thermal analysis), change the thermal
expansion from zero to 1e-05.
The thermal properties are able to be viewed by pressing on the tab named
Thermal. The Emissivity is given as a constant, however, the thermal
conductivity and heat capacity are functions of temperature. In order to see the
plot of thermal conductivity versus temperature, press the yellow highlighted
Table Entry Icon directly to the right of the thermal conductivity keyword. This
will show the tabular data and a plot of the thermal conductivity versus
temperature. Press OK when you are finished looking at the data.
The plastic flow stress data can be modified or entered to the Pre-Processor by
pressing the tab titled Plastic. Select the Flow Stress keyword to be a function
of effective strain, effective strain rate and temperature, which is the second
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Checklist
1. Loaded STEEL_S.KEY
2. Changed thermal expansion of object 1 (RING) to 1E-05
3. Defined the flow stress as a function of effective stress, effective strain rate,
and temperature
4. Loaded flow stress data AISI-1035
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Checklist
1. Defined velocity in Y direction to be zero at the corner node of object 1.
In order to select the thermal boundary conditions, press on the tab titled
Thermal. The default selection parameter for the thermal boundary conditions is
Heat Exchange with Environment. This function allows the user to set which
nodes on the surface of the object are exchanging heat with the surrounding
environment. In the case of this lab, the entire piece is exchanging heat with the
environment. Upon setting boundary conditions on an object it is important to
keep in mind that the program orients the starting and stopping points in a
counterclockwise fashion about the object. Click on any point on the boundary
of the object. You should observe the node highlighted and the word Start
should appear near that node. Now click on the node to the immediate clockwise
node of the selected node. The word End should appear next to this node. Now
click on the Generate BCCs Icon. This will generate the Heat Exchange with
Environment boundary conditions for this object.
At this point we have specified heat exchange with the environment, now we
need to specify values for convection and radiation. Click OK in the
BOUNDARY CONDITIONS window and then click OK in the OBJECTS
window. Click on the Simulation Controls Icon and then click on the Processing
Conditions button. Set the Environment Temperature to 1000 C and set the
Convection Coefficient to 0.1 N/(sec*mm*C). Now the thermal boundary
conditions are specified. Click OK in PROCESSING CONDITIONS and then
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Checklist
1. Set BCC heat exchange with the environment for the entire object.
2. Set Environment temperature to 1000 C and Convention Coefficient to 0.1
N/(sec*mm*C)
Checklist
1. Set object temperature to 20 C
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Step Selection
In order to select the step to be viewed, there is a step list on the right side of the
DISPLAY window. You can click on the step to select it, or you can you can
use the following buttons:
First Step
Previous Step
Play Backwards
Stop Playing
Play Forward
Next Step
Last Step
The First Step button will select the first step in the simulation, while the Last
Step button will select the last stored step. The Previous Step button will move
back one step in the simulation. The Next Step button will move forward one
step in the simulation. The Play button will display each step, pause for a
moment, and load the next step in the simulation. When it reaches the end of the
simulation, it will cycle back to the beginning and continue playing. The Play
Backwards button behaves the same as the Play button, but will display the steps
backwards, or in the opposite order. To stop either Play Forward or Play
Backward, you must click on the stop button. Click on the Temperature Hotkey
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button which looks like a thermometer . You can now view how the
temperature changes in the simulation. Experiment with these controls until you
feel comfortable with them.
Simulation Summary
You can see overall results of any step by clicking on the Summary button in the
CONTROL window. The SIMULATION SUMMARY window will appear.
This contains information on the current database. You can view information on
the given variables for any object in any step of the simulation. First select a
step from the Step list, and then the object from the Object list box. The text
boxes for each variable will show the current values for the step and object
selected. Click on the Variables tab to view the variables of interest such as
nodal temperature. Click on the Eye icon (plot min/max) to view how the
minimum and maximum temperatures changed with time in the simulation. Click
on the OK button until you return to the main post-processing window.
Contour Plots
In order to view a contour plot of the objects, just select the variable you wish to
view from the Hotkeys at the bottom of the CONTROL window. Click on the
Effective Strain button. The DISPLAY window should change and display a
line contour plot of effective strain. You can change the plot type from Line
Contour to Shaded Contour by clicking on the Shaded Contour icon. The plot
should change to a shaded contour plot. You can change the step shown by
selecting a new step from the step list.
Vector Plots
In order to view a velocity vector plot, just click on the Vector button in the
CONTROL window. The DISPLAY window should change to display velocity
vectors of all nodes in the mesh. You can also display more than one plot at the
same time. Click on the Viewport Options button next to the selection button
and select a dual horizontal viewport. The screen should split and display two
copies of the original viewport. Now click in the bottom viewport. The outline
should change from gray to green, signifying it as the active viewport. Any
changes you make will now apply to this viewport.
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6.6. Post-Processing 6
Checklist
1. Changed to directory RING
2. Loaded Step 50 of RING.DB database
Locate and click on the Simulation Controls button in the CONTROL window.
The SIMULATION CONTROLS window will appear. Locate the Operation
Name text box and title the simulation as Cooling. Click on the Stopping Step
button when you are finished. Set the number of simulation steps, NSTEP, to 20
and set the step increment to save, STPINC, to 4. Click OK in the STOPPING
and STEP CONTROLS window and then click OK in the SIMULATION
CONTROLS window.
Checklist
1. Named Operation Name Cooling
2. Set number of simulation steps to 20
3. Set the step increment to save to 4
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In this lab we will consider the case where the object is not subject to
uniform heat exchange boundary conditions.
Important Note:
It is very often the case in practice where some surfaces of an object
are subject to radically different thermal boundary conditions than
others. One example is the case of forced convection in which one
surface is incident of a high velocity fluid while the other sides do not
see a high velocity. The use of heat exchange windows can provide
localized definitions of heat exchange boundary conditions and allow
DEFORMTM to model this specific case.
User Caution:
For any boundary that is not covered by a heat exchange window, the global
values are used such as the emissivity specified in the material properties
and the convection coefficient specified in the processing conditions.
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For this lab, we will define four different windows, one for each surface.
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Use the third window to define the outer side of the workpiece. Make
sure that his window overlaps the adjacent window slightly and define
the environment temperature to be 20 C, the convection coefficient to be
0.02 N/(mm*s*C) and the emissivity to be 0.9.
Use the fourth window to define the boundary for the top of the
workpiece. Define the environment temperature to be 20 C, the
convection coefficient to be 0.01 N/(mm*s*C) and the emissivity to be
0.8. After this is completed, press OK in the HEAT EXCHANGE
window and then in the BOUNDARY CONDITIONS window and then
in the OBJECTS window.
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Checklist
1. Set Window 1: Environment temp: 20 C Convection Coef: 0.02
Emissivity:0.6
2. Set Window 2: Environment temp: 20 C Convection Coef: 0.09
Emissivity:0.8
3. Set Window 3: Environment temp: 20 C Convection Coef: 0.02
Emissivity:0.9
4. Set Window 4: Environment temp: 20 C Convection Coef: 0.01
Emissivity:0.8
Now that the data has been changed, the current step -51 must be added to the
current database. Click on the Database... button in the CONTROL window.
The DATABASE GENERATION window will appear. Make sure that the
Database Type is set to Old. If the type is New, then the old database will
be deleted when you generate step -51. Click on the Generate button to add the
current step, and click on the Yes button in the ADDING TO OLD DATABASE
window. Click on the OK button in the DATABASE GENERATION window
when you are finished. Exit the PRE-PROCESSOR and prepare to continue the
simulation.
From the SYSTEM window, click on the Simulation button. Once the
simulation has been started, monitor the simulation from the PROCESS
MONITOR window.
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6.6. Post-Processing
Click on the Post-Processor button to Post-Process the results of the simulation. You
should see the message like Figure 6.2. Click on the Yes button to load the database file.
Step Specification
For the exception of the very first step, the DEFORMTM Post-Processor will only show
the positive steps when loading a database. To show the negative steps in the Post-
Processor, click on the Steps icon. All available steps will be shown in the STEP
SELECTOR window. To make all the steps available, click on the All Steps button.
This will highlight all the steps in white. After this is done, click on the OK button. The
negative step will be shown now in the main Post-Processing window.
Point Tracking
To track certain points on the boundary of an object, click on the Point Tracking button
in the CONTROL window. The POINT TRACKING window will appear (Figure 6.3).
First you must define the points to track, so click on the Define Material Points and
Track button.
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The DISPLAY window should change and show an outline of object 1 and the
DEFINE/TRACK POINTS window will appear. To add a point to track, click
on the object where you would like to track a point. As you add points, their
coordinates will appear in the Defined Points Table in the DEFINE/TRACK
POINTS window (Figure 6.4).
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Set the first point in the upper right hand corner of the object. Now place a
second point in the center of the object. Place a third point in the lower left
corner of the object. If you make a mistake, you can delete a point by clicking
on the Delete Points button in the lower left corner of the Display window.
To add points again, just click on the Add Points button. Once all points have
been defined, click on the OK button in the DEFINE/TRACK POINTS window.
All points in the simulation will then be tracked (Figure 6.5).
To view point tracking graphs, you must create a secondary viewport. Select a dual
horizontal viewport from the Viewport Options button in the DISPLAY window.
Now click on the lower viewport to select it as the current viewport. To plot point
tracking data in this viewport, click on the Generate Point Tracking Graphs
button in the POINT TRACKING window. The POINT TRACKING GRAPHS
window will appear from which you can select the graph options as shown in Figure
6.6.
Set the Variable to Temperature and click on the OK button. The Time vs.
Temperature data for your simulation should now appear in the lower viewport
(Figure 6.7). Click on the OK button in the POINT TRACKING window.
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Now when you play through the steps, a vertical line will appear on the Time vs.
Temperature graph to indicate where the current step is on the graph. You can
zoom in on any area of the graph using the Dynamic Zoom and Zoom Window
buttons. You can also measure the difference in both time and temperature between
any two points on the graph user the Ruler button in the DISPLAY window. Once
you have finished viewing the data, exit the Post-Processor.
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Lab Objective:
The purpose of this lab is to acquaint the user with inputting properties required to
model a phase transformation in DEFORMTM. In this lab, the user will see how to define
in DEFORM the data necessary to model phase transformations for plain carbon steel.
A basic description of how transformation affects both deformation and heat transfer is
shown in Figure 7.1. As shown in the center of the relation in Figure 7.1, the operation of
all three nodes is a function of the carbon content of the steel. Since the concentration of
carbon may vary throughout the steel, the mechanical and thermal properties of the steel
will be non-homogenous.
Figure 7.1 shows a few example relationships and it is not intended to be exhaustive,
however, it does show that transformation is highly coupled to both deformation, heat
transfer and carbon content. In Figure 7.2, the relationships of four different phases of
plain carbon steel are shown. Austenite exists at higher temperatures while Martensite
and Bainite are metastable phases at lower temperatures. The metastable phases can be
produced by rapidly cooling Austenite. Each phase is defined by its own set of material
properties. These material properties define the plastic behavior of the phase, the thermal
properties of the phase, and possibly (if using an elasto-plastic material) the elastic
properties of the phase. The relationship between the transformation from one phase to
another is defined by the Inter-Material properties. This relationship is defined in terms
of a kinetics model (in order to determine rate of phase transformation) and a few
relational properties such as latent heat and volume change. The principle interest of the
user is how to make use of the data that exists in available tables and charts for a heat
treatment simulation. This is the ultimate goal of this lab. The key concepts for the user
to look for are:
1) What material properties are required to define a phase for the current simulation?
2) What data is required to describe the change between the phases?
3) How can one make use of existing tables and graphs for a DEFORMTM heat treatment
simulation?
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H e a t G e n e ra te d b y D e f o rm a tio n
C a r b o n C o n te n t
L a te n t
H eat
T e m p e r a tu r e in d u c e d
S t re s s in d u c e d T r a n s f o r m a tio n
T ra n s f o rm a tio n
T r a n s f o r m a tio n
P la s tic i ty
T r a n s f o r m a tio n
M artensite
(M aterial
Properties)
Inter-M aterial
Properties
A ustenite
(M aterial
Properties)
Inter-M aterial
Properties
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Checklist
1. Running DEFORMTM-2D in directory STEEL
Locate and click on the Simulation Controls button in the CONTROL window.
The SIMULATION CONTROLS window will appear. Set the UNITS to SI.
Locate the Simulation Title text box and title the simulation as STEEL_DATA
and then click OK in the SIMULATION CONTROL window.
Checklist
1. Titled Simulation Title as STEEL_DATA
2. Set units to SI
The purpose is to set-up all the material properties for three phases of steel and
to define them as a mixture. The three phases are Martensite, Bainite and
Austenite. These components combine to define the mixture, in this case, AISI-
1045 steel. In the material properties section we will define the elastic, plastic
and thermal data for each phase. These phases will define the mechanical
properties for the AISI-1045 steel using a weighted volume fraction of the
component phases. In this section of the lab, the user will input the required
material properties for Austenite (for use in an elasto-plastic material simulation)
and then load the rest of the material data from a file. It is important for the user
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to note that the purpose of this section is to become familiar with the
DEFORM interface.
Click on the Material Properties button in the CONTROL window. There will
be a default material group in the material properties section.
This will allow us to edit the values for Youngs Modulus, Poissons Ratio and
the coefficient of Thermal Expansion. The value of Young's Modulus will be a
function of atom content and temperature so click on the Constant/Function Icon
for Youngs Modulus to activate the Table Entry icon. Click on the Table Entry
Icon to open the TABLE ENTRY window. By default, the x-axis Data will be a
Constant, change this to Temperature and Atom. This will allow the Youngs
Modulus value to vary with respect to temperature and dominant atom content.
(In the case of steel the dominant atom content is carbon).
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The TABLE ENTRY window (Figure 7.3) is arranged so that the top two data
entry boxes specify the values of Atom Content and Temperature for which the
Youngs Modulus is defined. The data entry box located just below the center of
the TABLE ENTRY window defines the values for the Youngs Modulus for the
specified values of Atom Content and Temperature.
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1) Click in the upper left-most data entry box with Atom directly above it and
then click on the Insert Row icon. This will add another row to the Atom
Content variable.
2) Make the value for the first entry 0.14 and the second entry 0.6.
3) Now click on the data entry window directly to the right of the previously
edited window.
4) Click on the Insert Row icon five times to insert five extra values for
Temperature.
5) Type in the values of temperature 0, 200, 400, 600, 800 and 900, in
increasing order.
6) To enter the values for Youngs Modulus in the matrix, go to the matrix in
the lower portion of the TABLE ENTRY window and enter in the following
values:
Temp Atom
0.14 % 0.6 %
0C 204468 198580
200 C 192900 187361
400 C 175416 170415
600 C 152018 147742
800 C 122704 119342
900 C 114451 111347
7) Press the Apply button when you are finished with typing the above data in
the TABLE ENTRY window. You should see two curves in the DISPLAY
window.
8) Press the OK button.
Note that for a complete set of Elastic properties, the Poissons ratio and thermal
expansion coefficient would have to be defined. The same procedure would be
followed, however we will be loading the remaining elastic properties from a
keyword file later in the lab.
_ _ .
= ( , , T )
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Click on the Flow Stress Data icon to obtain the MATRIX DATA window.
Change the Temperature value to 20 C and add a row to both the Strain Rate and
Strain data entry windows. Input the value of Strain Rate to be 1.5 and 1.6 and
input the value of Strain to be 0.1 and 0.7. For the Flow Stress values, place the
following values in the matrix just below the center of the window.
Strain Strain Rate
1.5 1.6
0.1 688.963
688.963
0.7 904.711
904.711
Click on OK when all the flow stress values have been input to the system.
The definition of flow stress is the stress required to perform incremental plastic
deformation on a material. For example, if a material is being deformed plastically, the
effective stress in the material is determined from the flow stress data based on the
temperature, strain and strain rate at which the material is being deformed. Once the
plastic deformation is discontinued, the flow stress is the stress required to resume
plastic deformation.
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By clicking on the Material Properties icon, one can note that the fourth
material group is not a phase but rather a mixture of the first three material
groups. Thus, the material properties of the fourth group is determined by a
volumetric-weighting of the first three material groups. Click OK when you are
finished.
Click on the File option on the menu bar in the CONTROLS window and load
the Keyword file TRANS.KEY. This file is a TTT relation to be examined by
the user. In this section, due to the complexity of existing TTT diagrams the
user will just load the data and then look at the data carefully to gain an
appreciation on how to input data from an isothermal TTT diagram into the Inter
Material Properties section. Click on the Inter Material button in the CONTROL
window to bring up the INTER MATERIAL PROPERITES window. The
purpose of this window is to assign relationships between material
transformations from one material to another material. All the materials that are
defined in the Material Properties section are all seen at the top of the INTER
MATERIAL PROPERITES window. The purpose of this section of the lab is to
define the relationship of the transformation from Austenite to Bainite. This
transformation occurs during cooling, usually at a rather high rate.
1) Highlight the Austenite material in the Material 1 table by clicking on the
Austenite entry.
2) Highlight the Bainite material in the Material 2 table by clicking on the
Bainite entry.
3) In the Parameters section of the INTER MATERIAL PROPERITES window
note that the Phase1 Phase2 option has been defined already. This
defines that the austenite phase may transform into the bainite phase
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assuming that the process conditions satisfy the kinetics model specified for
the transformation.
4) The next specification required is which kinetics model to use to model the
transformation of Austenite to Bainite. The kinetics model used for this
transformation will be a diffusion model.
Click on the tab Kinetics and note the Kinetics model titled Diffusion f(Temp,
Stress, Atom). This model requires the user to input data in the form of an
Isothermal TTT diagram. Note that there are three values that can be specified
in the Kinetics selection window. These values are the Avrami exponent n, the
beginning transformation (Curve 1) curve and the ending transformation curve
(Curve 2). In order to understand the model, lets look at a graphical
representation of the model. Click on the Data icon.
The model specified requires data input in the form of a TTT diagram, either
defined with one curve and the Arvami equation or two curves. In the case of
two curves, the first curve is a plot of temperature versus time for a specified
value of initial phase volume fraction (specified by the Curve 1 VF variable).
This volume fraction could be set to 1 % or less, but it must be greater than zero.
The second curve is a plot of temperature versus time for a specified value of
final phase volume fraction (specified by the Curve 2 VF variable). This volume
fraction could be set to 99 % or greater. DEFORMTM can predict the amount of
transformation at a given effective stress and dominate atom percentage from the
inputted plots (See Figure 7.4 for an example curve).
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Figure 7.4 shows a simplified TTT diagram. It shows a TTT diagram for a
transformation from phase 1 to phase 2 at an effective stress of 300 MPa and a
carbon content of 0.44 wt %. The curve on the left side of the plot is the initial
volume fraction and the curve to the right is the volume fraction. The Display
window will look like Figure 7.5. (It is important to note that the time is in log
base 10, not in seconds). There are six curves in diagram covering three carbon
concentrations and an initial and final phase transformation. In this case, the
start curve is 1 % transformation and the final curve is 99 % transformation.
These values are can be seen in the INTER-MATIERAL window. The number
of curves used in the model is specified in the upper left of the Matrix Data
window. If the number of curves in the Matrix Data window is set to two, then
the Avrami n number specified in the previous window is not necessary.
However, if only one curve is specified, then an Avrami n number is required
to give DEFORM sufficient information to solve for volume fraction.
After the user has sufficiently perused this feature, press OK to return to the
INTER MATERIAL PROPERITES window. Click on the Transformation Tab.
The Latent Heat is defined to be 595.36. Latent Heat is the amount of heat
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From the CONTROL window, click on the Disk Icon next to the Keyword name
to save this session as a keyword file.
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Go to the File option in the menu bar and load in the keyword file,
MAT_TTT.KEY. This will provide you with all the material properties for the
next three labs.
Click on the Simulation Control icon in the Controls window. Set the following
parameters:
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12) Now click on the Advanced Step Controls to modify the stepping criteria
of the simulation. Change the temperature change per step to 5 C and the
Temperature change time step to a range of 2 s and 20 s.
13) The Step Definition should be changed to temperature based by selecting
the Temp option in the radio button.
14) Press Ok in the Advanced Step Controls window, press Ok in the Stopping
and Step Controls window.
15) Click on the Processing Conditions button in the Simulations Controls
window and set the Environment temperature to 850 C.
16) Set the value of the Convection Coefficient to 0.1 N/(s*mm*C).
17) Press Ok in the Processing Conditions window and press Ok in the
Simulation Controls window.
This is a method by which the time step size is determined by using the
calculated temperature gradient from the previous step to estimate a user defined
maximum temperature change. The parameters that need to be set are the
desired maximum temperature change, the largest allowable time step size and
the smallest allowable time step size. Also, the Step Definition needs to be
changed to Temp in order that the first step of the simulation DTMAX is
calculated while the rest of steps are determined from the temperature field.
Object #1:
At this point, the user will insert all the objects required for this
simulation.
We need to load the workpiece geometry and create a mesh for it.
2) Change the Object name to Gear Tooth.
3) Click on the Geometry button in the Objects window and load the
IGES file TOOTH.IGS.
4) After the gear tooth has been loaded reverse the geometry to make it
counter-clockwise.
5) Click on the Check Geometry button to ensure that the geometry is
legal.
6) Click Ok in the Geometry window.
7) After this, click on the Mesh icon in the Objects window.
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Set the number of mesh elements to 500 and adjust the weighting factor for the
meshing such that boundary curvature has a weighting factor of 1 while leaving
the other weighting factors unchanged. Set the number of thickness elements 4
and the maximum size ratio between elements 3.
8) Generate the mesh for the gear tooth and press Ok.
9) Set the Material type Elasto-Plastic.
10) Click on the Boundary Conditions icon and set the vertical velocity
to zero for the bottom section. (Figure 8.1).
11) Click on the thermal tab in the Boundary Conditions window to set
the heat exchange boundary conditions (Figure 8.2).
12) Set the thermal boundary conditions to Heat Exchange with the
Environment for the outside part of the tooth and the bore (inner)
section.
13) Press Ok when finished when applying these boundary conditions.
14) Click on the Material icon to bring up the Material Selection
window. This is the window in which the material type is selected
for a particular object.
15) Click on the AISI-1045, COLD selection and press Ok.
At this point the temperature and the phase composition of the object needs
to be defined.
Question: What are weighting factors and why are they necessary?
Weighting factors are variables that one can assign in order to emphasize or deemphasize
the density of the mesh based on object parameters. By increasing the weighting factor for
boundary curvature, the mesh generator will tend to place more elements in regions where
the boundary of the object has higher curvature.
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17) Click on the Objects Tabs, then click on the Elements Data Icon and click
on the Transformation Tab to see where the composition of the object
material is defined. (Figure 8.3)
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This window specifies several values in for the object phase composition. The
value, VOLFC, is the volume fraction of a specific phase in the object. The sum
of the volume fraction values for all the phases at any time must be equal to
unity. The user can initialize the object to be pure Bainite at the beginning of the
simulation by clicking on the VOLFC value for the Bainite phase and then
clicking on the Initialize Values icon directly to the left. Click on the Bainite
box to make it the active box and click on the Initialize button (I) next to the
table. Set the value to 1 and click on the Ok button. Initialize the VOLFS
variable for Bainite to be unity as well, following the same procedure. The
VOLFS variable specifies the transformation limit of a given phase. Thus, by
specifying a value for VOLFS of 1.0, 100 % of the Bainite is allowed to
transform into Austenite.
18) Press Ok in the Initialize Elements window and then press Ok in the
Elements window.
19) Click on the Properties icon in the Objects window and change the EP
Initial Guess to Use previous step solution.
20) Click Ok in the Object Properties window.
Object #2:
This object will be used for the sole purpose of constraining object 1.
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1) In the Objects window, add another object by clicking on the Add Object icon. This
object number will default to 2.
2) Select this object 2 and change the name of this object to Plane.
3) Click on the Geometry icon in the Objects window and click on the Load IGES file
icon.
4) Load the file Plane.IGS as object 2 and press Ok in the Geometry window. Your
screen should look like Figure 8.4.
The purpose of this object is to serve as a plane of symmetry where no material may
cross. The key to making this act as a true plane of symmetry is to set the interface heat
transfer to zero, the friction to zero and the placing a no seperation criteria between the
two objects. These parameters will be prescribed later.
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The new state variable to investigate in this type of simulation is the Volume
Fraction variable. Click on the State Variable icon and select the variable
Volume Fraction under the Mic tab. You will see that you will be given the
option to select four components, which represent the possible phases and the
mixture component. Select the Bainite component and plot the variable as a
shaded contour. The user should see the variable initially having a value of 1.0
(which means 100 % of the structure is composed of Bainite) and eventually
falling to 0.0 (which means 0 % of the material is composed of Bainite). The
user should plot the other volume fractions to determine which component the
volume was converted to.
In addition, you should look at the volume change of the object as a function of
time. Click on the Simulation icon to open the Simulation Summary window.
Click on the eye icon next to the word Volume. A plot of the Volume as a
function of time should appear in the Display window. Click on the Ok button to
close the Simulation Summary window. Zoom in on the area of interest using the
zoom window function to observe how the transformation changed the volume
of the object. It should be noted that the transformation decreases the overall
volume of the object because austenite is the FCC structure while bainite
consists of lathe plates of ferrite (BCC structure) and cementite (orthorhombic
structure). FCC is a closed packed structure and hence smaller in volume than
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either BCC or any orthorhombic structure, therefore the volume of the object
will decrease when bainite transforms into austenite which can be observed in
the plot.
Austenite Transformation
107.0
Op 1 Op 2 Op 3
106.5
106.0
105.5
Volume
105.0
Op 4
104.5
104.0
103.5
0.E+00 3.E+03 6.E+03 9.E+03 1.E+04 2.E+04
Time (sec)
Figure 8.5 shows a complete heat treat process. Notice that when the workpiece
transforms to Austenite the volume decreases because of the transformation
(BCC --> FCC). The curve changes slope (i.e. the volume begins to increase) as
a result of the continued heating of the workpiece.
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Create a directory called Carburize, move to that directory, type DEFORM2 and press ENTER.
The DEFORM System Window will appear. Enter the Pre-Processor to define your
simulation data. Click on the Pre-Processor button. The DEFORM Pre-Processor will
appear consisting of the Display window, the Control window, and the Message window. To
continue an old problem you have to start from the last saved step in the old database. Change
the Problem ID to Carburization. Go to the top menu bar and click on File. Select Load
Database and load the database TRANSFORM.DB. The Select Database Step window will
appear with a list of available steps to import. Select the last step and click on the Ok button.
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1) Click the Objects icons and click the Boundary Conditions icon in the Objects window.
At this point the user needs to define the boundary over which the carbon
bearing atmosphere is exposed to the workpiece. In this, the entire surface, both
the outer surface and the bore surface, will be exposed to a carbon-bearing
environment.
2) Click on the tab titled Diffusion and click on the icon titled Diffusion with the Environment.
3) Select and generate boundary conditions for both the bore of the gear and the outer surface of
the gear (Figure 9.1).
4) Press Ok in the Boundary Conditions window and in the Objects window.
The user needs to define the following parameters in order to run a carburization
problem.
1) Set Diffusion to Yes.
2) Initialize carbon concentration in the material.
3) Set the reaction rate of the material.
4) Set the environmental atom content of the atmosphere.
5) Set the Diffusion Boundary Conditions for exchange with the environment.
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Click on the Ok button in the Objects window. Click on the Save Keyword icon.
The new state variable to investigate in this type of simulation is the Dominant
Atom variable. Click on the State Variable icon and select the variable
Dominant Atom under the Dif tab and plot the variable as a shaded contour. The
user should see the variable having an initial uniform value of 0.14. The value
increases at the free boundaries to indicate the carbon absorbed and diffused into
the gear tooth.
Create a directory called Diffusion, change to that directory, type DEFORM2 and press ENTER.
The DEFORM-HT System Window will appear. Enter the Pre-Processor to define your
simulation data. Click on the Pre-Processor button. The DEFORM-2D Pre-Processor will
appear consisting of the Display window, the Control window, and the Message window. To
continue an old problem you have to start from the last saved step in the old database. Change
the Problem ID to Diffusion. Go to the top menu bar and click on File. Select Load Database
and load the database Carburization.DB. The Select Database Step window will appear with a
list of available steps to import. Select the last step and click on the Ok button.
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processor information to see if a database can be generated. If there are no errors shown, then
the database can be generated. Click on the Generate Icon to generate the database.
State Variables
The state variable to investigate in this simulation is again the Dominant Atom variable, which is
located under the Dif tab. Click on the State Variable icon and select the variable Dominant
Atom and plot the variable as a shaded contour. The user should see the variable in the same
state as in the end of the Carburization operation. In this simulation, the total amount of carbon
holds constant but diffuses throughout the gear tooth.
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Create a directory called Quench, change to that directory, type DEFORM2 and
press ENTER. The DEFORM-2D System Window will appear. Enter the
Pre-Processor to define your simulation data. Click on the Pre-Processor button.
The DEFORM-2D Pre-Processor will appear consisting of the Display
window, the Control window, and the Message window. To continue an old
problem you have to start from the last saved step in the old database. Change
the Problem ID to Quench. Go to the top menu bar and click on File. Select
Load Database and load the database Diffusion.DB. The Select Database Step
window will appear with a list of available steps to import. Select the last step
and click on the Ok button.
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generated. If there are no errors shown, then the database can be generated.
Click on the Generate Icon to generate the database.
State Variables
DEFORM allows the user to make use of Jominy curve data. DEFORM will
compute the cooling rate for each element and make a hardness estimate based on the
Jominy curve. The method of specifying Jominy curve data is
1) Specify hardness estimation type under Objects/Properties to Using Jominy
Curves.
2) Go to Material Properties and click the Hard tab. Select the mixture material and
make the Cooling Time a function.
3) Click on the Table Entry in the Cooling Time and enter the Cooling Time versus
Distance of the Jominy bar data.
4) Click on the Jominy Curve Data icon and enter the Hardness versus distance data.
This will fully specify the required information for the hardness estimation.
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12.1 Introduction
Due to the complexity during deformation, the DEFORM grain model does not compute dynamic
recrystallization simultaneously. The dynamic recrystallization that would have occurred during
deformation is actually computed at the step right after the deformation. Meta-dynamic and
static recrystallizations occur during non-deforming time. This means the users will not see any
results unless the deformation simulation is followed by a non-deformation simulation (usually
heat-treatment). To simulate a complete microstructure evolution, the workpiece should be
sufficiently cooled at the end of simulation.
This lab models a simple upsetting process followed by air-cooling and water quenching. The
problem is axisymmetric and uses SI units. The workpiece material is IN718, and the die
material is steel H-13.
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Peak Strain:
Temp. a1 n1 m1 Q1 c1 a2
0 4.659e-3 0 0.1238 49520 0 0.83
Grain Growth:
Temp. M a9 Q9
0 2 9.44e+19 467114.7
These data can be a function of temperature or strain rate. The first column of the matrix
specifies the temperatures or strain rates of the data. If the data is independent of temperature or
strain rate, the value of the first column is insignificant.
Input 300 in Temp Limit, which prohibits Grain Modeling under this temperature. Keep 0 in
Strain Retaining Coef. Click OK and exit.
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DEFORM-Heat Treatment Wizard Lab
3. Import geometry 2
4. Generate mesh 2
5. Material definition 2
6. Workpiece initialization 2
7. Medium definition 3
8. Schedule definition 5
9. Simulation control 5
Problem Summary:
This lab will demonstrate how to use the Heat Treatment Wizard to conveniently prepare a
multiple-stage heat-treatment simulation. Phase transformation of the material (JIS S45C) will be
simulated. Multiple zones of heat-transfer coefficients are assigned to the workpiece.
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3. Import geometry
In page Geometry, choose import from a geometry, KEY, or DB file and click Next.
Load geometry file QUENCH_PART.IGS.
4. Generate mesh
In page Mesh Generation, use 500 for unstructured mesh. Use 2 layers of structured
surface layer, set "Thickness mode" to be "ratio to object overall dimension", and 0.005
and 0.01 for thickness of layer 1 and 2, respectively. Click Next. (The structured
surface mesh helps provide better thermal solution accuracy with less computing time.)
5. Material definition
In page Material, choose Load from material library and click Next. Pick a
material with appropriate thermal data (and phase transformation data if necessary). In
this case, we use JIS-S45C(Heat Treatment) in the Steel category.
6. Workpiece initialization
In page "Workpiece initialization", for temperature, choose "Uniform" and set 900 C. For
phase volume fraction, choose "Uniform" and set 1.0, 0, and 0 for Austenite, Pearlite, and
Martensite, respectively.
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7. Medium definition
In page Media details, you will define various media and heat transfer zones associated
with them.
1) Rename the first media to air and set the default heat transfer coefficient (HTC) to
constant 0.05.
2) Add a media Water. For its "default" HTC, load data from file
"WATER_HTC1_si.DAT".
3) Add one more heat transfer zones for media Water. Click on the object boundary to
specify the start and end points of the zone. The zone is assigned to the bottom of the
workpiece as shown below. For Zone #1 HTC, load data from file "
WATER_HTC2_si.DAT".
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Click the button "Define functions", you can view and edit the HTC as a function
temperature as shown in the dialog below.
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8. Schedule definition
In Schedule page, input a five-stage quench schedule as below. A procedure like this is
sometimes referred as "Intensive Quenching", which is designed to create a very thin
"crust" of Martensite on the part. Such a process can achieve high surface hardness with
relative low part distortion. Click Next.
9. Simulation control
In "Step Definition", the default settings are good.
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Click "Finish" button to generate Database file and multiple operation control file.
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DEFORM-Inverse Heat Transfer Wizard Lab
3. Import geometry 2
4. Generate mesh 2
5. Material definition 2
6. Initial temperature 3
8. Thermal history 4
14. Optimization 8
Problem Summary:
This lab will demonstrate how to use the Inverse Heat Transfer Wizard to determine heat
transfer coefficients of between workpiece and media during a heat transfer process. Temperature
measurement data are needed. Heat transfer coefficients can be functions of temperature or time.
Multiple zones of heat-transfer coefficients are assigned to the workpiece.
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3. Import geometry
In page Geometry, choose import from a geometry, KEY, or DB file and click Next.
Import geometry file SIMPLE_INVHEAT.IGS from labs2d directory.
4. Generate mesh
In page Mesh Generation, use 100 for unstructured mesh. Use 2 layers of structured
surface mesh, set "Thickness mode" to be "ratio to object overall dimension", and 0.01 and
0.02 for thickness of layer 1 and 2, respectively. Click Next. (The structured surface
mesh helps provide better thermal solution accuracy with less computing time.)
5. Material definition
In page Material, choose Create a new material and click Next. In the Material
Wizard, you only input thermal data: 0.1 for Thermal Conductivity, 0.2 for Heat
Capacity, and 0.3 for Emissivity. You dont need to save the material in library.
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6. Initial temperature
In page Initial temperature", for workpiece choose "Uniform" and set 600 F. For
Environment, choose constant 68 F.
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8. Thermal history
In Thermal History page, load a file SIMPLE_INVHEAT_Thermal_History.DAT.
Click Apply to see the graphs. Input 10 seconds for Process End Time. Click
Next.
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In page Heat transfer coefficient function definition (II), all defaults are fine. Click
OK.
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14. Optimization
In Optimization page, click Start. The optimization may take up to a few hours, and
you can activate the background command prompt to see program output.
After the first iteration is completed, you can see the history of the objective function on
the left. Also you can click Next to view current optimization results.
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2. Initialization 2
3. Import geometry 2
4. Generate mesh 2
5. Material definition 3
6. Workpiece initialization 5
7. Medium definition 5
8. Schedule definition 8
9. Simulation control 9
Problem Summary:
This lab will demonstrate how to simulate a complex tempering heat treatment problem of
a steel part. This lab can also help users understand and capabilities and limitations of DEFORM-
HT's phase transformation calculation scheme.
In this lab, the problem is set up using the Heat Treatment Wizard, as multiple stages are
involved in the heat treatment. Theoretically, this type of problem can also be set up in the regular
Pre-Processor, but with less convenience and greater flexibility.
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2. Initialization
In the "Initialization" dialog, set the "Unit System" to SI, and set "Geometry Type" to
Axisymmetric. Turn on "Deformation", "Diffusion", and "Phase Transformation". Click
"Next".
3. Import geometry
In page Geometry, choose import from a geometry, KEY, or DB file and click Next.
Go to directory Labs/HeatTreat, and load geometry file TemperingPart.GEO.
4. Generate mesh
In page Mesh Generation, use 300 for unstructured mesh. Use 2 layers of structured
surface layer, set "Thickness mode" to be "ratio to object overall dimension", and 0.005
and 0.01 for thickness of layer 1 and 2, respectively. Click Next. (The structured
surface mesh helps provide better thermal solution accuracy with less computing time.)
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5. Material definition
In page Material, choose Import from .DB and .KEY and click Next. Import
material "Demo_Temper_Steel.KEY" from directory labs/HeatTreat.
You can click button "Advance" to view and edit the material and transformation data.
Note that this is a complex mixture material with eight constituents (phases), including
Austenite (A), Pearlit+Banite (PB), Martensite (B), Ferrite (F), Low-temp. Martensite
(LM), Temper Banite (TB), Temper Ferrite+Cementite (TFC). The transformation
kinetics between the phases include A->F, A->PB, A->TB, A->M, PB->A, M->LM, M-
>A, LM->TFC, TB->A, and TFC->A. Among these kinetics, A->F, A->PB, A->TB, M-
>LM, and LM->TFC are diffusion-controlled defined by TTT curves. A->M uses
Martensitic transformation model, and PB->A, M->A, TB->A, and TFC->A use
simplified diffusion model. In addition, A->F has an equilibrium volume fraction that
depends on carbon contents.
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6. Workpiece initialization
In page "Workpiece initialization", for "Temperature", choose "Uniform" and set 20 C.
For "Atom", choose "Uniform" and input 0.2. For "Phase volume fraction", choose
"Uniform" and set 1.0 for "Pearlite + Banite", and zero for the rest.
7. Medium definition
In page Media details, you will define various media and heat transfer zones associated
with them.
1) Rename the first media to Furnace and set the default heat transfer coefficient
(HTC) to constant 0.1.
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2) Add a media Polymer Solution. For its "default" zone, define the HTC as a function
of temperature as follows:
Temperature HTC
20 3.5
400 8.5
700 15
900 5.2
3) Add a heat transfer zone to the media Polymer Solution. Click on the workpiece
boundary to specify this zone using the "start-and-end-point" selection mode. The zone
should be on the bottom of the workpiece as shown in the graph. Define HTC as a
function of temperature as follows:
Temperature HTC
20 3.5
200 4.5
400 8.8
700 3.5
900 2.8
4) For media Polymer Solution, deactivate "Radiation". Specify the "Diffusion Surface
Reaction Rate" as a function of temperature as follows:
Temperature HTC
20 0.1
500 0.2
1000 0.6
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3) Add one more media Air. Input 0.02 for the default HTC.
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8. Schedule definition
In Schedule page, input a five-stage schedule as explained below.
1) One hour (3600 s) of furnace heating. The temperature of the furnace is specified as a
function of time. This function can be input by clicking the corresponding "Define" cell in
the "Advance" column.
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2) 10 minutes (600 s) of quenching in the polymer solution. Specify the "Atom" content to
be 0.8.
9. Simulation control
In "Step Definition", change "Temp. change per step" to 2. Accept other default settings.
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Click "Finish" button to generate Database file and multiple operation control file.
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1. In this problem, A->F transformation has equilibrium volume fraction that depends on
atom content. The carbon content is high near the surface due to diffusion from the
environment, therefore, very low F is formed there. In the interior, more F is formed, and
A->F transformation competes with A->PB. (This is because in our kinetics data, both are
diffusion controlled and active within the similar time-temperature range.)
2. Maximum residual stress was high after quench (~1320 MPa), and reduced after
tempering (~400 MPa).
3. After quench, M is near 0.8 on the surface. It reduced to 0.03 after tempering. Most of
M has become LM and TFC.
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