AFDEX 2012 Examples

Adviser for Forging process Design EXpert
AFDEX3D User Training Manual

ORMING ETAL IMULATION
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1 2 3 4 5 6 7 8 9 10
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Table of Content
Cold Upsetting Process Cold Forging Process Cold Former Forging Process Hot Forging Process Hot Former Forging Process Piercing Process Trimming Process Sliding Die Process
3D Continuous Analysis from 2D Analysis Result Process

Free Forging Process
2
Cold Upsetting
Problem Definition
Problem Type: Isothermal Analysis, Cold, 1 Step Analysis Area : 45 Workpiece Condition Die Condition
72.7
0.22
kg/mm2 (AISI1010)
Die Shape : See the picture below

Coulombs Law of Friction (=0.05) Die Speed: Constant Velocity (Upper : -1.0 mm/s, Lower : 0.0 mm/s)
180.0
Circular Section Rod Cut Workpiece Cross-section area: 45.0mm X 60.0mm Initial temperature: room temperature
90.0
60.0
Initial Workpiece Shape
Final Location of the mold
<Forging Process>
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30.0
30.0
30.0
Inserting Process Information
1. After running AFDEX3D/Pre, click on New icon. 2. After setting Analysis title, Forging type(COLD), Simulation Type(3D) and Units type(1), click "OK"
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Preprocessing input window
1. As shown in the image above, the preprocessing input window appears where you can adjust settings for Workpiece as well as, Die shape, Forging condition, and etc.
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Workpiece Shape Settings

1
Right click
Workspace Window
1. Right click on the Workspace Window 2. Click on Model Auto shape, then the window number 2 will appear on the screen. 3. Select in Type of shape and insert Radius:45.0, Height:60.0, Angle:45.0 then press "OK".
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Open Die Information
Right click
1. Right click on the Workspace Window. 2. Click on Model From File and the window as shown above in number 2 will appear. 3. Select the Modeled die shape *.stl file and click Open.
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Workpiece Deformation Resistance
1 2 Right click
1. Right Click on the Workspace Window. 2. Click on Material From Library. Load Steel AISI 1010.
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Inserting Die Speed
Right click
1. Right Click on the Workspace Window. 2. Click on Press Manual, and the window as shown above in number 2 will appear. 3. Adjust Die speed: Input-1.0mm/s in Y-axis direction, then click "OK.
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Adjusting Friction and Contact Condition
Right click
1. Right Click on the Workspace Window.. 2. Click on Friction Manual, and the window as shown above in number 2 will appear. 3. Friction Condition and Contact Limit: Input Coulomb Friction=0.05, Touch Limits=AUTO, then click "OK"
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Applying Changed Settings
1. Drag the changed settings onto Project explorer
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1 Double click
View Model Analysis
1. Double click on Stage 1 in Project explorer, and view target model.
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Die Position Initialization
1. On the left bar, click on the Positioner icon. 2. Click on Auto then press OK to reset die position.
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Symmetry Plane Setting
1 2 Double click 3
2 Planes
1. Double click on Stage 1 Symmetry_Plane, and the window as shown in picture above will appear. 2. Click on the planes like shown in number 3 then click OK.
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Processing Condition Setting

3
Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Type 30.0mm under Distance, and then click on to set the reference point.
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Run Analysis
3
Right click 2
1. Right click over the process name, and the following window 1 will appear. 2. Click on Simulation Run. You can select the save location and file name to save. 3. After saving, command prompt will appear to begin analysis.
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Cold Forging Process
18
Problem Definition
72.7
0.22
kg/mm2 (AISI1010)

Cylindrical Rod Cut Workpiece Cross-section area: 14.0mm X 16.0mm Initial temperature : room temperature
28.0
16.0
Initial Location of the Mold
Final Location of the Mold 19
<Forging Process>
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Open Die and Workpiece Information

1
Right click 2
Workspace Window
1. Right click on the Workspace Window. 2. Click on Model From File and the window as shown above in number 2 will appear. 3. Select the *.stl file of the modeled workpiece and die and click Open.
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2
Right click
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Inserting Die Speed
2 Right click
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Right click
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1 Double click
View Model Analysis
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1 2 Double click 3
2 Planes
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3
Double click
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Run Analysis
3
Right click 2
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Cold Former Forging Process
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Problem Definiton
Problem Type: Isothermal Analysis, Cold, 4 Steps Analysis Area : 90 Workpiece Condition Die Condition
72.7
0.22
kg/mm2 (AISI1010)

Coulombs Law of Friction(=0.05) Die Speed: Constant Velocity (Upper : -1.0 mm/s, Lower : 0.0 mm/s)
Cylindrical Rod Workpiece Cross-section area : 16.3mm X 32.6mm Initial temperature: room temperature
32.6
32.6
Stage 1
Stage 2
Stage 3
Stage 4
<Forging Process>
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1
Right click 2
Workspace Window
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Right click
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Inserting Die Speed
1
2
Right click
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1 2 Right click
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Add Stage
Right click
1. Right click on the process name. Click on Insert Stage to add a stage 2. Repeat until you have enough number of stages.(Ex: In case of 4 stages, repeat 3 times.)
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1 Double click
View Model Analysis
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1. On the left bar, click on the Positioner icon. 2. Click on Auto then press OK to reset die position. The rest of the stage will reset automatically
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1 Double click
2 3
2 Planes
1. Double click on Stage 1 Symmetry_Plane, and the window as shown in picture above will appear. 2. Click on the planes like shown in number 3 then click OK. The rest of the stages will automatically adjust.
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3
Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Type 20.0mm under Distance, and then click on to set the reference point. 3. For each stage, click on Forming and repeat the procedure. (Stage 2=16.8mm, Stage 3=12.5mm, Stage 4=4.5mm)
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Run Analysis
3
Right click 2
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Hot Forging Process
47
Problem Definition
Problem Type: Isothermal Analysis, Hot, 2 Steps Analysis Area : 45 Workpiece Condition Die Condition
6.44
0.2
kg/mm2 (AISI1018)

Cylindrical Rod Workpiece Cross-section area : 16.0mm X 47.0mm Initial temperature : 1200oC
32.0
47.0
Stage 1
Stage 2
< Forging Process >

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1. After running AFDEX3D/Pre, click on New icon. 2. After setting Analysis title, Forging type(HOT), Simulation Type(3D) and Units type(1), click "OK"
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1
Right click 2
Workspace Window
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2
Right click
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Inserting Die Speed
2 Right click
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Right click
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Add Stage
Right click
1. Right click on the process name. Click on Insert Stage to add a stage 2. Repeat until you have enough number of stages.(Ex: In case of 2 stages, repeat once.)
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1 Double click
View Model Analysis
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1 Double click
2
3
2 Planes
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3
Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Type 15.0mm under Distance, and then click on to set the reference point. 3. For each stage, click on Forming and repeat the procedure. (Stage 2=6.6mm)
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Run Analysis
3
Right click 2
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Hot Former Forging Process
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Problem Definition
Problem Type: Isothermal Analysis, Hot, 3 Steps Analysis Area : 30 Workpiece Condition Die Condition
6.44
0.2
kg/mm2 (AISI1018)

Cylindrical Rod Workpiece Cross-section area : 16.0mm X 70.2mm Initial temperature : 1200oC
32.0
70.2
Stage 1
Stage 2
Stage 3
< Forging Process >

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1
Right click 2
Workspace Window
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Right click
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Inserting Die Speed
1 2 Right click
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2 Right click
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Add Stage
Right click
1. Right click on the process name. Click on Insert Stage to add a stage 2. Repeat until you have enough number of stages.(Ex: In case of 3 stages, repeat twice.)
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1 Double click
View Model Analysis
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1 Double click
2
3
2 Planes
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3
Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Type 62.3mm under Distance, and then click on to set the reference point. 3. For each stage, click on Forming and repeat the procedure. (Stage 2=45.7mm, Stage 3=9.0mm)
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Run Analysis
3
Right click 2
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Piercing Process
77
Problem Definition
Problem Type: Isothermal Analysis, Cold, 2 Steps(with Piercing) Analysis Area : 30 Workpiece Condition Die Condition
72.7
0.22
kg/mm2 (AISI1010)

28.0
16.0
Stage 1
Stage 2-Piercing
< Forging Process >

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1
Right click 2
Workspace Window
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1 2
Right click
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Inserting Die Speed
1
2 Right click
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Right click
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Add Stage
Right click
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1 Double click
View Model Analysis
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1 Double click
2 3
2 Planes
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Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Type 5.7mm under Distance, and then click on to set the reference point. 3. For each stage, click on Forming and repeat the procedure.
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Processing Condition Setting-Piercing

3
Double click
1. Double click on Stage 2 Forming, and the window as shown in picture 2 above will appear. 2. Type 5.0mm under Distance, and then check Piercing/Trimming. Click on to have window 3 to appear. 3. After picking two points to stroke, click OK then click OK on window 2.
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Run Analysis
3
Right click 2
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Trimming Process
93
Problem Definition
Problem Type: Isothermal Analysis, Cold, 4 Steps(with Trimming) Analysis Area : 30 Workpiece Condition Die Condition
72.7
0.22
kg/mm2 (AISI1010)

21.6
Initial Workpiece Stage 1 Shape
105.0
Stage 2
Stage 3
Stage 4-Trimming
< Forging Process >

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1
Right click 2
Workspace Window
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Right click
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Inserting Die Speed
1 2 Right click
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Right click
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Add Stage
Right click
1. Right click on the process name. Click on Insert Stage to add a stage 2. Repeat until you have enough number of stages.(Ex: In case of 4 stages, repeat 3 times.)
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1 Double click
View Model Analysis
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1 Double click
2 3
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3
Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Type 106.6mm under Distance, and then click on to set the reference point. 3. For each stage, click on Forming and repeat the procedure. (Stage 2=75.3mm, Stage 3=72.5mm)
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Processing Condition Setting-Trimming
Double click
1
1. Double click on Stage 4 Forming, and the window as shown in picture 2 above will appear. 2. Type 1.48mm under Distance, and then check Piercing/Trimming. Click on to have window 3 to appear. 3. After picking two points to stroke, click OK then click OK on window 2.
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Run Analysis
3
Right click 2
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Sliding Die Process
109
Problem Definition
72.7
0.22
kg/mm2 (AISI1010)

Coulombs Law of Friction (=0.05) Die Speed : Time dependant velocity
90.0
72.0
Stage 1
< Forging Process >

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1
Right click 2
Workspace Window
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2
Right click
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Inserting Die Speed-Upper1
2 Right click
1. Right Click on the Workspace Window. 2. Click on Press Manual, and the window as shown above in number 2 will appear. 3. Adjusting Die Speed: Input time(52) and -1.0mm/s in y-direction, then click "OK". (Click Add to insert speed frame.)
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Inserting Die Speed-Upper 2
2 Right click
1. Right Click on the Workspace Window. 2. Click on Press Manual, and the window as shown above in number 2 will appear. 3. : 2 y -0.5mm/s , "OK" . (Click Add to insert speed frame.) 4. Right click on the speed and select Rename to distinguish each speed.
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Right click
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Add Upper Die
Right click
1. Right click on Stage 1 and select Insert > Upper Die to add the upper die.
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1 Double click
View
1. Project explorer Stage 1 , .
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1. Click on Tools Positioner to initialize each die position. 2. Click on Stage 1 to activate workpiece, upper die and lower die then uncheck Upper in Chain as shown above. Click on Auto under Positioning 3. When the window 3 appears, click Ok. The position of workpiece and die will reset as shown above. 4. Click OK in window 2. The rest of the stage will reset automatically.
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1 Double click
2 3
2 Planes
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2 1 Double click
1. Double click on Stage 1 Forming, and the window as shown in picture 2 above will appear. 2. Change the Elapsed Time under Stop Criterion and insert 52 seconds under Time. Click "OK.
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Run Analysis
3
Right click 2
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3D Continuous Analysis from 2D Analysis Result Process
125
Problem Definition
Problem Type: Isothermal Analysis, Cold, Step 1-2D, Step 2-3D Analysis Area : Step 2-60 Workpiece Condition Die Condition
72.7
0.22
kg/mm2 (AISI1010)

3D Analysis AFDEX3D
2D Analysis AFDEX2D 180.0 90.0 30.0 30.0 30.0 Step 1 Final Shape
60.0
3D Transformation
Step 2 Final Shape
< Forging Process >

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Open 2D Analysis Result
1. After running AFDEX2D.exe, click on File Open and the window will be displayed as shown above. 2. Select *.srf file format and open a 2D analysis result.
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Confirm 2D Analysis Result
1. The 2D analysis result will appear.
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Transform to 3D
1
1. Click on Interface 2D to 3D and the window will appear as shown in picture above. 2. Select*.srf file format, and then select 2D analysis result to open. If opened, window 3 will appear. 3. Input number of segments and degree, then click OK. Command prompt window will appear. (Transformed 3Dfiles will be named as same as the 2D file with the addition of _2D3D at the end )
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Open Transformed File
1. After running AFDEX3D/Pre, click on File Open and the window will appear as shown above. 2. Select the *.a3dsrf file format and open the transformed file.
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3D Result Confirmation
1. The 3D file converted from 2D will be displayed as shown in picture above.
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Changing Filename
1. Copy the transformed file into another folder(3D). 2. Change the end of filename to 3D.a3dsrf.
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1. Activate Project explorer, Workspace windows.
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1
Right click 2
Workspace Window
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2
Right click
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Inserting Die Speed
2 Right click
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Right click
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Add Stage
Right click
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1. Drag the changed settings onto Project explorer 2. Because 3D Analysis only starts from 2nd stage, change 2nd stage only.
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View Model Analysis
1 Double click
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2 3 1 Double click
2 Planes
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1 Double click
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First Step and Die Switch Option
Right click
1. Right click on Process Control and the Properties will appear. Click on it to open window 2. 2. Enter the end of 2D analysis for first step(IS) in which case, 47. Click on Advanced to open window 3. 3. Select +1 for die change option then click OK. Click "OK for window 2.
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Run Analysis
3
Right click 2
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Free Forging Process
146
Problem Definition
Problem Type: Isothermal Analysis, Hot, 1 Step Analysis Area : 360 Workpiece Condition Die Condition
7.56
0.188
kg/mm2 (AISI1018)

Coulombs Law of Friction (=0.3) Die Speed : Cycle motion (Upper : Variable, Lower : Variable)
Round bar Workpiece Cross-section area : 100.0mm X 100.0mm Initial temperature : 1250oC
30mm
y
100.0
x
Workpiece needs to be located above x-axis
< Forging Process >

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80.0
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1
Right click 2
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2
Right click
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die
-160mm/s
Workpiece and Die Movement Setting

- Because the die is initially 30mm away from the workpiece, the final diameter will be 80mm if transformed at the rate of 40mm per 1 second. - Because the die moves for 0.25 seconds, as shown on the left, the speed is 160mm/s and the period is 1 second
Before setting PRE, draw a speed versus time graph of workpiece and die movement.
0.249
0.25
0.5
0.75
160mm/s 0.251 0.499
workpiece(Rotation)
40/s 0.501 0.749
0.25
0.5
0.75
- This determines the rotational speed of the workpiece. - If the workpiece is to rotate 10 degrees per second, we can set it to 40 degrees per second for 0.25 second.
workpiece(Translation)
0.751 20mm/s
0.25
0.5
0.75
- This determines the linear speed of the workpiece. - If the workpiece is to move 5mm per 1 second, we can set it to 20mm per second for 0.25 second.
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Inserting Die Speed(Die-1)
Right click
1. Right Click on the Workspace Window. 2. Click on Press Manual, and the window as shown above in number 2 will appear. (Because the die motion is cyclic, change the type to Cyclic motion.) 3. Die speed setting : Enter the time and speed value from the previous page
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Inserting Die Speed(Die-2)
Right click
1. Right Click on the Workspace Window. 2. Click on Press Manual, and the window as shown above in number 2 will appear. (Because the die motion is cyclic, change the type to Cyclic motion.) 3. Die speed setting : Enter the time and speed value from the previous page (Die2 and Die1 are opposite directions. Also, workpiece movement is adjusted in User-routine.)
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Right click
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1 Double click
View Model Analysis
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Progress Condition Setting
1
Double click
1. Double click Stage 1 Forming to open a window shown in picture above. 2. Change to Elapsed time then input 10 seconds as shown in picture above.
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Progress Condition Setting
1. Click on Volume & Mesh and change to All-direction. Select User defined under Elements and input 10000. 2. Click OK to finish.
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Save Analysis Study File
1. Click on File Save As to save all the Input files. 2. SCF file for User-routine is created in the save location.
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SCF User-routine Setting

19 -3 2 1 19 -8 2 1 : Free Forging Option : Remesh Option
1. Open the SCF file with Notepad to edit.
1 179.9999 0.25 0.5 2.5 50 11 179.9999 0.25 0.5 2.5 50
: Up until here are files created from PRE

: From here are the parts for workpiece movement setting
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SCF User-routine Setting

1 0.0 50.0 2.0 0.0 1 Forging Stage Number 0.0 Initial x-axis location of workpiece 50.0 Area of Analysis(Usually contact size of die) 2.0 Default value 0.0 Default value 1 0 0 0.0 7
1 1 2 1 2
500 0.0 500 1 2
0.0 3 Lines represent directional vector
1 Forging Stage Number 0 Default value 0 Default value 0.0 Default value 7 Number of points to be edited below 1 0.000 0.0 0.0 0.0 0.0 2 0.500 0.0 0.0 0.0 0.0 . 1 Serial Number 0.000 Time 0.0 Rotational Speed 0.0 Speed in x-axis 0.0 Speed in y-axis 0.0 Speed in z-axis 1.0 0.0 0.0
0.0 1.0 0.0 0.0 -1.0 0.0
1 Forging Stage Number 500 Total Number of Cycles 1 1 Cycle Indication 0.0 Current Cycles distance in its directional vector 500 500 Cycles Indication 0.0 Current Cycles distance in its directional vector 1 1 500 0.0 500
0.0
1 Forging Stage Number 500 Total Number of Cycles 1 1 Cycle Indication 0.0 Current Cycles moving distance in x direction
1.0 Period 0.0 Final process analysis time 0.0 Default value Must save after editing. 162
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Run Analysis
1. Double click on the *.bat file in saved folder to run analysis. 2. Open *.a3dsrf to examine the analysis result.
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AFDEX 2012 Examples

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AFDEX 2012 Examples

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Adviser for Forging process Design EXpert

AFDEX3D User Training Manual

3D Continuous Analysis from 2D Analysis Result Process

Die Shape : See the picture below

Initial Workpiece Shape

Final Location of the mold

Inserting Process Information

Preprocessing input window

Workpiece Shape Settings

Open Die Information

Workpiece Deformation Resistance

Inserting Die Speed

Adjusting Friction and Contact Condition

Applying Changed Settings

1. Drag the changed settings onto Project explorer

View Model Analysis

1. Double click on Stage 1 in Project explorer, and view target model.

Die Position Initialization

Symmetry Plane Setting

Processing Condition Setting

Cold Forging Process

Die Shape : See the picture below

Initial Workpiece Shape

Initial Location of the Mold

Final Location of the Mold 19

Inserting Process Information

Preprocessing input window

Open Die and Workpiece Information

Workpiece Deformation Resistance

Inserting Die Speed

Adjusting Friction and Contact Condition

Applying Changed Settings

1. Drag the changed settings onto Project explorer

View Model Analysis

1. Double click on Stage 1 in Project explorer, and view target model.

Die Position Initialization

Symmetry Plane Setting

Processing Condition Setting

Cold Former Forging Process

Die Shape : See the picture below

Initial Workpiece Shape

Inserting Process Information

Preprocessing input window

Open Die and Workpiece Information

Workpiece Deformation Resistance

Inserting Die Speed

Adjusting Friction and Contact Condition

Applying Changed Settings

1. Drag the changed settings onto Project explorer

View Model Analysis

1. Double click on Stage 1 in Project explorer, and view target model.

Die Position Initialization

Symmetry Plane Setting

Processing Condition Setting

Hot Forging Process

Die Shape : See the picture below

Initial Workpiece Shape

< Forging Process >

Inserting Process Information

Preprocessing input window

Open Die and Workpiece Information

Workpiece Deformation Resistance

Inserting Die Speed