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Unformatted text preview: ME363 Forming Project (100 homework equivalent points) Due Date: Nov. 22, 2011 Introduction A metal forming software (AFDEX‐2012) will be used in this project to design and simulate the metal forging process. AFDEX is a general purpose metal forming simulator, which can be applied not only to conventional bulk metal forming process including forging, rolling, extrusion and drawing but also new creative bulk metal forming process. AFDEX is theoretically based on rigid‐thermoviscoplastic finite element method. It can solve the metal flow problem and heat transfer in metal forming and die structural analysis problem. Purpose Learn to use the metal forming software to design and analyze the metal forming process under specific requirements. Software AFDEX‐2012 (Adviser for Forging Design Expert) has been installed on the computers in ME 2028. From the desktop, go to Start → Programs → AFDEX‐2012 and then click on AFDEX‐2012. When the software is ready, proceed as described below. Task 1 Tutorial Follow the tutorial provided on the class website to be familiar with the metal forming software AFDEX‐
2012. This tutorial will guide you through the steps to simulate a forming process with a simple geometry. Once the simulation is finished, you can check the stress, strain, temperature, load, power, etc, with the post processing module of the software. Task 2 Forming Process Design Workpiece Solid cylindrical billet Design Requirement The height of the workpiece is to be reduced by 50%. 1 Experimental Procedure 1.
4. Create workpiece geometry with a diameter of 50 mm and a height of 30 mm. Create upper and lower die geometry with a diameter of 100 mm and a height of 30 mm. Select AISI 316 stainless steel (20oC) from the material library for the workpiece. Select the press type. Part A – Effect of Friction Coefficient 1. Set the friction to 0.3. 2. Set the stop criteria according to the design requirement specified above. 3. Run the simulation. 4. Measure the maximum diameter or radius of the deformed workpiece. Refer to Fig. 1 to see the measurement method. 5. Repeat steps 1‐4 with a friction coefficient of 0.05. 6. Record the maximum diameter and comment on the effect of friction coefficient on the barrel shape. Fig. 1 Measurement of the maximum radius of the deformed workpiece 2 Part B – Effect of Hot and Cold Forging 1. Set the process forming type to hot. 2.
5. Change the material to AISI_316SS (T=600‐1200C). Set the coefficient of friction to 0.05. Run the simulation and record the final load. Return to the project file from part A and compare the final load values Part C – Multiple Stroke Design of Cold Forging 1. Set the friction to 0.05. 2. Design the forming parameters to optimize the process and ensure the power level does not exceed 2000W and the cycle time is under 10 Seconds. 3. Effective Stress level does not exceed 400 MPa. Hint: 1. Take advantage of the symmetry of the geometry to save computational time. 2. Try to change the velocity history of upper die to optimize the process. 3. Use multiple stages in the setup for Part C of Task 2. 3 Items to be included in the report (Report must be typed) Please follow the format of the report posted on the class website. The items listed below are required on your final report: 1. Problem set‐up for each case and a summary of table showing the parameters used for simulation. 2. Simulation results: a. Part A: show the effect of friction coefficient on the barreling, load (and power) vs. stroke curve. b. Part B: show the effect of cold and hot forging on the barreling and load vs. stroke curve. c. Part C: show your final design and optimization process. 3. Analysis of the results is needed in all three parts. 4. Conclusion: A brief summary of the project and conclusions drawn from the project. Comments on the project: Please evaluate the project and provide your comments on the project on a separate sheet of paper. This part will not be counted in the grade of the project. However, your comments are appreciated in improving the design of the project for future class. 4 ...
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