modeling (with pro-e) and simulation (with ansys, deform3d) - cold molding

[rory_the_king]

Good evening, everyone.
I'm bumping into a cold molding station for the production of an insert.
that attached is the first station (among the 5 totals) in which the piece, starting from a cylindrical bar, is deformed.
now the question is:
I would like to try a deform or ansys simulation to check the first station (in terms of maximum deformation and maximum voltage) and/or optimize it, but what to model and what parts to use in simulation?
Does anyone have any suggestions?
greetings and thanks to all!
Lorenzo

 

[lucacort]

Are you referring to the efforts and deformations of the equipment or to the deformed piece, or both? ?

If the only ones related to the deformed piece, I think you don't have to model the tools (considered rigid), and to simplify the fact that there is a myable matrix you could try to study the deformation on the contrary or as if it were all in matrix (even if I think there are tools to simulate the spring thrust matrix).

 

[rory_the_king]

I thought of modeling the matrices 21 and 49 (composed of a container and a hazelnut, therefore with binding interference), the two punches and the piece to deform.
of course I am interested in both the equipment and the deformed piece analysis: It is however of interest to analyze the duration of wear-resistant components and therefore deteriorate before!
I will also have to trace in some way the speed with which the matrices move!in Italy there are various types of molding machines.
Does anyone have any data to suggest?
and for friction coefficients to be set?
greetings to all and thanks
Lorenzo

 

[lucacort]

In my opinion the left sting should only work as an extractor, not during the deformation phase.
for speed I would suggest a value between 60 and 100 strokes/min


p.

long ago I was interested and passionate about these simulation software. . .
...then, unfortunately, my company was not inclined to investment.

 

[rory_the_king]

I'm going to go on deform tomorrow, and I'm starting to write a few things so we're discussing it!
Hello and thank you
Lorenzo

 

[rory_the_king]

here is the modeling of the parts:
- hazelnut matrix sx (002.0021)
- matrix hazelnut dx (001.0049)
- Punzone sx (005.0067)
- Punzone dx (005.0066)
- to deform.
I try to set up with these five parts!
Hi.
Lorenzo

 

[rory_the_king]

I forgot the annex

 

[lucacort]

In my opinion, you should also take into account the sharpness in the slab due to the threading (always that obviously do not start from a recoct thread that you already know the tension state).

I unfortunately have a version of proe less recent than your (wf3) and I can't open your files.

 

[rory_the_king]

one of the very first steps (deform-3d simulation control parameters setting) is to define:
- the simulation type;
- the simulation mode.
As far as the type of simulation changes, there are 5 types:
- "lagrangian incremental": used for conventional molding appliqués, heat transfer and thermal treatments. Transitional phases related to processes such as lamination, removal of truciole, extrusion, drawing can be modeled with this type of simulation.
- "ale rolling": used for lamination processes. automatically generates the boundary conditions for the entry and exit surface of the "billetta".
- "steady-state machining": There is also a template here where the initial model can be set to "Lagrangian charms". where there is a sufficient generation of chips, the template can be used to generate an additional operation that can change the "mode" to "steady state".
- "ring-rolling": able to model the non isothermic process of lamination with rings.
- "staedy-state extrusion."
regarding the "mode" (can also be used together):
- "heat transfer": simulates thermal effects within the simulation, including heat exchanges between objects and the environment, and internal heat generations due to phase transformations, where applicable;
- "deformation": simulates deformations due to thermal, mechanical phenomena and phase transformations;
- "transformation": simulates a transformation between phases due to temporal and thermo-mechanical effects;
- "diffusion": simulates the diffusion of c atoms to the intent of the material, due to gradients of c concentration;
- "grain": simulates calculations of grain grade and re-crystallization;
- "heating": simulates heat generation due to resistance or induction.

choice as setting:
type: lagrangian incremental
mode: deformation
As a hypothesis I have neglected heat exchanges because molding operations are so fast that heat exchange cannot happen.
Do you agree with me on this?
Thank you all!
I hope I've been clear!
Lorenzo

 

[rory_the_king]

Attached what is done until now!
Hi.
Lorenzo

 

[eddy]

Hello, everyone. a few years ago I participated in the demo of the deform simulator, but unfortunately our company did not acqistato.
if possible let us know the size of the starting wire and the shank to be extruded. also the quality of steel. based on this data you can calculate the extrusion ratio and assess whether the springs of the sliding matrix manage to endure the extrusion effort. If the sliding matrix race is shorter than 10 mm you can opt for gas springs (cilindri at nitrogen).
for the speed of the press the parameters are many, from the size of the machine, the piece, steel quality, lubricants, etc.. I believe from 120 to 160 pz/min
from the overall I can not understand what type of press is, personally however I prefer to use the matrices with sliding container with plug, rather than fixed matrix container with sliding inner bushing.
We'd have to talk until tomorrow.
for now I say hello to you

 

[Giorgio29]

hi, lorenzo, I know I answer you a bit late but I hope that my advice will still be useful to you: anzys allows to modify both heat exchange, phase changes, acoustics, we from computational devices to facilitate structural analysis and simplify the prototyping phase also for those subject to load conditions. I agree with your theory of modifying Part 21 and 49.

Bye!