Ring-Rolling Lab

Ring Rolling Lab

Open DEFORM-3D. Make a new problem under Problem directory. Problemsetup window will open. Select the ring rolling guiding template

Select under problem home directory and name it: ring-rolling-lab.

Ring-Rolling Lab

(Ring rolling preprocessor will open up)Click Next to open operation and name operation rolling 1 and click Next.

The available options in Thermal calculations page are Calculate temperaturein ring only (non-isothermal) and Constant temperature (isothermal). Use Constanttemperature (isothermal) in this lab. Click Next to go to the Workpiece shape page.

Select the default Simulate whole part in Workpiece shape page and clicknext.

Ring-Rolling Lab

In the Number of objects page, Note the current default objects. Click Next togo to the Workpiece ring object page. Leave the temperature for the ring at 700 Fand click Next.

In the Geometry 2D cross-section page, there are three options that the usercan use to generate the cross section geometry for the ring and rolls. Select Use 2Dgeometry primitives and select the hollow cylinder. Use 2X2 in2 as cross-section with0.25 as fillet radius and (6,0) as origin. Create the geometry and close the primitivewindow.

Ring-Rolling Lab

The user also has the options of using Import geometry and/or tableinputting/editing 2D geometry other than importing 2D geometry.

Now, click Next to go the mesh generation page. Notice the 2D cross-section isdisplayed in 3D and the revolving axis for 3D-mesh generation would be the Z-axis.

Use 100 elements for the 2D cross-section mesh and generate the 2D mesh.There are other parameters for 2D-mesh generation by clicking the Advanced button.

Ring-Rolling Lab

Use the default 100 sections for 3D mesh and generate the ring mesh by clickingGenerate 3D mesh.

Ring-Rolling Lab

There are display options to turn On/OFF 3D mesh, 2D geo and mesh, and Slicingon the page.

Click Next to go to Material page, and pick AISI-1035 Cold from the materialdialog by clicking import material from library and selecting Steel category. Then,go to the next page for driving roll definition.

In the object page, leave object name as driving roll and go to the next page,which is the 2D cross-section geometry page. Click Use 2D geometry primitive andselect the hollow cylinder. Use 5 X 10 in2 as cross-section and (14,0) as origin. Create thegeometry and close the primitive window.

Ring-Rolling Lab

Click Next, go to the Geometry 3D page. Click Preview digitized 2Dgeometry and the imported geometry is discretized and the discrete points are shown.Use the default 200 revolving sections, and generate 3D geometry.

Ring-Rolling Lab

Notice there are options to change digitizing parameters by clicking on the setup button. There are also display options to turn On/Off 2D and 3D geometries.

Click Next to go to the position page. Click Object positioning to positionthe driving roll. The ring and the driving roll are displayed in sliced view for bettervisualization. Choose offset as the positioning method. Move the workpiece by 4 inchin Z direction and hit the apply button. Once the positioning is done, click OK to exitthe positioning dialog. Then, click Next to go to the Movement page.

Ring-Rolling Lab

Define rotational movement for the driving roll as a constant of 2 rad/sec. Noticea green rotation arrow showing rotational direction in the display window.

Ring-Rolling Lab

Click Next to go to the object page for pressure roll (Mandrel). Keep the nameof pressure roll unchanged and just click Next to go to the 2D cross-section geometrypage.

Click Use 2D geometry primitive and select the cylinder. Use 2X10 in2 ascross-section. Create the geometry and close the primitive window. Go to the 3Dgeometry page and generate 3D pressure roll geometry.

Go to the position page, and use interference positioning and input 0.0001 asinterference tolerance and Y as the approach direction to position the pressure roll withthe workpiece as the reference.

Ring-Rolling Lab

Go to the movement page and input 0.01 in/sec speed and 0 torque on pressureroll. Use preview movement to visualize the movement of the driving roll and pressureroll.

Click Next to go to Control page, the select generate all to generatecontacts between driving roll and the workpiece as well as between pressure roll and theworkpiece.

Ring-Rolling Lab

Click Next to go to the Stopping control page, and enter 10 secs for theprocess duration.

Go to Step control page and leave the defaults there and go to the Generatedatabase page. Click Check input to verify everything is OK. Select Generatedatabase to generate the ring rolling database.

Ring-Rolling Lab

Save the project. Close the operation, and exit the ring-rolling template. Selectthe Run command in the simulator panel and start the ring-rolling simulation.