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DEFORM3D_v10.2_PreformDesign_Manual
DEFORMTM-3D Preform Design LabPREFORM DESIGN LAB1. Introduction to Preform
Design module 2. Initial Preform Design Scheme 3. The Preform Modification
Scheme1 2 8
D PreformDesign Lab1. Introduction to Preform Design moduleIn 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 dimensional preform shape.TMPreform Design module
in DEFORM-3D is a special tool to design initial preformshape from final forged
shape. In this process 3 dimensional CAD model will be used as an input and the
designed 3
dimehttp://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.htmlnsional preform
shape is an output as well. The output can be a STL file or DEFORMTM-3D Keyword
format so it is ready to run a simulation.Another nice feature of Preform Design
module is the feature of modification. Once simulation result is obtained,
modified preform shape can be obtained by using Preform Design module as
well.Figure 1: Typical preform (blocker) shape design in rib-web type (Dash
lines – forged shape, solid line – preform shape)1
D PreformDesign Lab2. Initial Preform Design Scheme2.1. Overview of the scheme
of designing initial preformFor a given final part configuration, there are
three steps to generate an initial preform shape. 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. Filtering
processhttp://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.html - The
resulting surface will be passed through a filtering procedure to produce a
smoothed shape. In the filtering procedure, the geometric domain will be
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converted into a frequency domain by using a Fourier transformation. By using
the filtering function, high frequency regions (sharp corners, edges, or small
geometric details of a surface) will be removed. An inverse Fourier
transformation will then be applied to obtain a “smoothed” surface. 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.
DigitizingFiltering Final forged shape CAD model (STL) Digitized
geometryTrimmingDesigned Preform shapeSmoothed geometry By filtering
methodFigure 2: Proposed initial preform design scheme2
D PreformDesign Lab2.2. Lab for Initial Preform Design SchemeStep 1. Start the
new DEFORM interface and
creathttp://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.htmle a New
Problem. Choose Preform as Problem Type. Click “Next”Figure 3: Problem Setup
WindowStep 2. Select “create a new preform shape” Step 3. Select model type
Full model - choose this, if upper and lower part is different Upper part only -
choose this, if upper and lower is symmetry Step 4. Choose geometry file by
clicking “Browse” Following format can be used as an input STL
GEO (AMGGEO file) PDA (Patran file) NAS (Nastran file) UNV (IDEAS file) IGS (2D
IGES) DEFORM Keyword DEFORM DB3
D PreformDesign LabStep 5. Define parting surface (i) Planar parting surface
casePick a point on parting surface (ii) Non-planar parting surface case –
requires additional parting surface definition (Shown as read color in
below)Figure 4: Defining Parting SurfaceStep 6. Digitizing - choose the
resolution Step 7. Define volume ratio – currently only “use flash model” is
available4
://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.htmlDEFORMTM-3D
PreformDesign LabStep 8. Define flash model On clicking “Preview” after input
flash thickness (T) and flash width (W), system will calculate volume ratio
value and display.TWFigure 5: Defining Flash Model.Step 9. Define filtered shape
Alpha value ~ adjust smoothness Scale value ~ adjust height ( normally
1.0)Figure 6: Smoothing GeometryStep 10. Define preform shape Distance from
outer boundary (D) ~ (-) inside cavity, ( ) outside cavity Draft angle (A) ~
degree, positive value5
D PreformDesign LabA DFigure 7: Defining Preform ShapeStep 11. Prepare preform
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geometry By stitching upper and lower preform shape (for full mode case) By
mirroring (for upper model case)Figure 8: Preparing Preform Geometry6
D PreformDesign LabStep 12. Meshing (if necessary)Figure 9: Mesh GenerationStep
13. Save preformFinisher PreformFigure 10: An
examhttp://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.htmlple of designed
preform shape7
D PreformDesign Lab3 The Preform Modification SchemeOverview of the scheme of
modifying the preform 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.
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 2.DEFORMTMSimulationInitial preform geometrySimulation result Desired
resultUpdatingPreformAnalyzingModified preform geometry Geometric changes to
preformFigure 1http://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.html1:
Proposed Preform Modification SchemeReference: Jin Yong Oh, Jae Bong Yang, Wei-
Tsu Wu, Hugo Delgado, “Finite Element Method Applied to 2D and 3D Forging
Design Optimization”, NUMIFORM 20048
D PreformDesign Lab3.1Lab for The Preform Modification SchemeStep 1. Choose
existing preform problem or create a new preform problem from TM DEFORM -3D
main. Step 2. Select “modify preform shape Step 3. Go to Import simulation
result page Select database name Select step Select objectFigure 12:
Import Simulation ResultStep 4. Check position ~ if we needFigure 13:
Positioning9
D PreformDesign LabStep 5. Result analysis Put tolerance value for calculation
and click “Calculate” button Current implementation can handle only under-fill
area. [Shown as “Flash (-)”]Under filling areaFigure 14: Analyzing Simulation
ResultStep 6. Smoothing preform modification
geometryFighttp://www.wenkuxiazai.com/doc/5768d646e518964bcf847c90.htmlure 15:
Smoothing Modified Geometry10
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DEFORMTM-3D PreformDesign LabStep 8. Create modified preform Put volume change
limit to control the amount of the volume that will be added.Figure 16: Creating
Modified Preform.Step 9. Prepare preform geometry ~ same Step 10. Generate mesh
~ same Step 11. Save preform ~ sameModified preform Volume addedInitial
preformFigure 17: An Example of Modified Preform Shape11
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