Spinning Lab

In this Lab we will be setting up simple Spinning process with ALE model and Implicit solver

1.1. Creating a New Problem

1.2. Process Page

1.3. Simulation setup

1.4. Objects

1.5. Workpiece

1.6. Mandrel

1.7. Tail stock

1.8. Roll

1.9. Pass Table

1.10. Controls

1.11. Contact

1.12. Stopping Controls

1.13. Simulation controls

1.14. Generate Database

1.15. Running Simulation

1.16. Post processing

Creating a New Problem

On a Windows machine , go to the button select DEFORM-v1x.xxx (.xxx indicates version number E.g. v14.0.2) and select DEFORM GUI Main vxx.xx from the menu. The DEFORM GUI Main window will appear.

Create a new problem either by selecting File **New Problem** or by clicking the New Problem icon. The Problem Setup window will appear as shown in Fig. 3DSPL1.1. Select “ Integrated Manufacturing Process “ radio button and Unit system as “SI “ using radio button. Define Problem Name as “SpinLab “ and make sure the “Show option dialog” check box is turned on (if we do not turn on the “Show option dialog ” check box, then we will not get the New Project dialog in MO UI). Then click on button to open a new Problem using the Deform Integrated Manufacturing Process.

New Problem page

Multiple operation wizard will open with the New Project dialog, At this point user will be prompted to specify a project name (system will create a separate folder with this project name) and title for this session. In this session we will use ‘SpinLab’ as the project name. 3D Spinning operation can also be added in “New Project” dialog, in this lab we will add Spinning g operation from Explorer operation list, so do not check “First operation” check box in “New Project” dialog. Click on to continue to open the operation.

Add 3D Spinning operation from the Explorer Operations list. Add the operation by clicking on button available next to 3D Spinning or user can also add by drag and drop into the Operation Editor (see Fig. 3DSPL1.2.). When we add the Spinning operation, If the current Screen upward direction is “Z” direction then we will get below popup. Click “YES-Change “ in “Change screen upward axis” popup.

Screen upward direction popup

Now the process settings window will open by default. 3D Spinning operation can also be added from Operation Explorer in MO.

Opened 3D Spinning operation

Process Page

In Process page select “Spinning “ and define Mandrel Rotationalspeed as 90 rpm as shown in Fig. 3DSPL1.4. This speed is also applied to both tail stock and head stock if we used. Click on to Simulation setup page.

Process page

Simulation setup

In Simulation setup, select solution method as “ALE “ and solver type as “Implicit “. Since, we are not interested in temperature profile we will select “Constant temperature (isothermal) “ type Thermal calculation and Turn on Active in FEM check box to activate Target volume calculation (see Fig. 3DSPL1.5.). Click on to Objects page.

Simulation setup page

Objects

In this spinning lab, we will use Workpiece, Mandrel, Tail stock and one Roll. In Objects list, by default Mandrel, Tail stock and Head stock check box will be checked. Uncheck the Head stock check box and keep Number of Rolls as 1 as shown in Fig. 3DSPL1.6. Click on to Workpiece page.

Objects list

Workpiece

In the Workpiece page, keep the object name as Workpiece , object temperature of 20°C and Object type as Plastic as shown in Fig. 3DSPL1.7. Click on to 2D Geometry page.

Workpiece General page

Importing Workpiece 2D Geometry

Import 2D geometry, “SpinLab-blank.DXF ” from the “3D/Labs/Spinning” folder. Click on and then click on Check and correct geometry in the pop-up to verify the geometry. The geometry will be corrected for its orientation, click in the message pop-up window and then ok button to close the geometry verification window. Click on to Mesh page.

Generating Mesh

In mesh page, select mesh type as Brick mesh and define Target number of Elements as 90 for Cross section mesh. For 3D mesh define Number of revolved sections as 100. Since the set up is ALE implicit we need finer mesh at contact for capturing accurate contact hence, we will define Finer Mesh in the contact region by 15 degree Angle and Size ratio as 4. Click on and then click on . The mesh should look like as shown in Fig. 3DSPL1.8. Click on to Material page.

Generated 3D Mesh for Workpiece

Assign Material

In Material page, click on (Load material from library) icon and load the material Steel group material “AISI-1010,COLD[70F(20C)] “ from material library window. Assign the “AISI-1010,COLD[70F(20C)] “ material for Workpiece as shown in Fig. 3DSPL1.9. Click on until Mandrel page.

Assigning Material for Workpiece

Mandrel

In the Mandrel General page keep the default values for name as Mandrel and temperature as 200°C. Click on to Geometry 2D cross-section page.

Importing Mandrel 2D Geometry - Cross section

Import 2D geometry, “SpinLab-mandrel.DXF ” from the “3D/Labs/Spinning” folder. Click on and then click on Check and correct geometry in the pop-up to verify the geometry. The geometry will be corrected for its orientation, click ok in the message pop-up window and then click button to close the geometry verification window. Click on to 3D Geometry page.

Generate Mandrel 3D Geometry

Using default value of 100 as “Number of revolved sections” generate 3D geometry by clicking on option (see Fig. 3DSPL1.10.). Click on to Reference point setup page.

Generated Mandrel 3D Geometry

Mandrel Reference Page

In this page we can define Reference point of Mandrel, we will use default calculated value of D “-63.5” as shown in Fig. 3DSPL1.11. “D” is the distance between the Deform Origin and the origin of the Mandrel along X axis and will be used to position the mandrel. Click on to Tail Stock page.

Reference point setup page

Tail stock

In the Tail stock General page keep the default values for name as Tail stock and temperature as 200°C. Click on to Geometry 2D cross- section page.

Importing Tail stock 2D Geometry - Cross section

Import 2D geometry, “SpinLab-tailstock.DXF ” from the “3D/Labs/Spinning “ folder. Click on and then click on in the pop-up to verify the geometry. The geometry will be corrected for its orientation, click ok in the message pop-up window and then button to close the geometry verification window. Click on to 3D Geometry page.

Generate Tail stock 3D Geometry

Using default value of 100 for “Number of revolved sections “ generate 3D geometry by clicking on option (see Fig. 3DSPL1.12.). Click on to Roll page.

Generated Tail stock 3D geometry

Roll

In the Roll General page keep the default values for name as Roll and temperature as 200°C. Click to 2D cross- section page.

Importing Roll 2D Geometry - Cross section

Import 2D geometry, “SpinLab-roll.DXF ” from the “3D/Labs/Spinning “ folder. Click on and then click on in the pop-up to verify the geometry. The geometry will be corrected for its orientation, click ok in the message pop-up window and then button to close the geometry verification window. Click on to 3D Geometry page.

Generate Roll 3D Geometry

Using default value 100 for “Number of revolved sections “ generate 3D geometry by clicking on option (see Fig. 3DSPL1.13.). Click on to Orientation page.

Generated Roll 3D geometry

Orientation

In this lab the movement of the roll along the mandrel axis is defined using path movement which requires roll datum to be defined. It should be noted that rolls require a unique setup approach due to their use of the path movement control. Roll translation will be defined by a path that is applied in a local UV (axial/radial) coordinate system. A single point on the roll, the reference point (datum), will follow this path. The current location of the reference point, and thus the roll, is determined by the path data and the current time. Each roll following a path must have a reference point defined for it.

User can select the Roll datum point using the button next to Roll Datum field (see Fig. 3DSPL1.15.) which will provide options as shown in Fig. 3DSPL1.16. User can also enter the Datum Co-ordinates manually. In this lab, Rotation center will be selected in Roll Datum wizard dialog, path definition for the roller are already properly configured according to the origin (0,0) reference point hence we will leave Roll Datum co-ordinates to default (0,0).

Orientation page

Roll Datum Wizard

The roll needs to be tilted to the proper spinning orientation, which is 45 degrees in this case. To do so, in Orientation page define Orientation angle as 45 as shown in Fig. 3DSPL1.16. and click . Click on to Pass Table page.

Roll Orientation page

Pass Table

Click on button to define Movement for Roll 1 in Pass table (see Fig. 3DSPL1.17.).

Path Table window

Since the roll moves along a particular path we will select Path and definition of path type as Function of Time path type as shown in Fig. 3DSPL1.18.

Note that curvilinear G-Code path data must be reduced to linear data, since DEFORM does not support curvilinear paths.

Roll 1 Movement page

Click and click to open SpinLab-roll-path_table.dat. from/3D/Labs/Spinning folder. Change the plot type to U-V to see a graphical representation of the axial (U) and radial (V) roller movement profile (see Fig. 3DSPL1.20.). Click in Synchronization with path movement popup and click to close the definition.

Synchronization with path movement popup

U-V Plot

Note that the Rotation 1 center point is already defined by the path translation data.

Select Rotation type as “Torque “ for Roll 1and leave the value at 0 since the roll rotates based on torque free. Click on to close movement page. We will not define any other values for this lab and click on to Positioning page.

Controls

All of the objects that are mounted along the machine axis (headstock, mandrel, workpiece, tailstock) were imported at the correct location.

Automatic positioning issue

Go to Controls page, then click on Automatic Positioning. Initial (t=0) option will move the roller to the path location of time = 0. At contact option will move the roller to the path location of the time at contact. Use At contact and click on . Click in popup. Click on to close Contact page.

Automatic positioning window

Contact

In Contact page, select “User “ type and click on button. In table we will observe default relations being added, turn on sticking check box for Mandrel -Workpiece and Tail stock - Workpiece relations. Now define Shear friction value of 0.12 and click on button. Click on button to calculate default contact tolerance value and Generate contact by clicking on button. Select Yes in “STICKING CONDITION” popup. Generated contact which looks like as shown in Fig. 3DSPL1.23. Click on to Stopping controls page.

Contact page

Stopping Controls

Define Process Duration as 22 sec as shown in Fig. 3DSPL1.24. Click on to Simulation controls page.

Process Duration page

Simulation controls

EnterNumber of steps as 999999 , Step increment to save as 50 and Time per step as 0.001 sec in Simulation controls page as shown in Fig. 3DSPL1.25. Click on to Generate DB page.

Simulation Controls page

Generate Database

In Generate DB page, click on the button to generate the database. Observe the message in Message tab informing database generation status.

Running Simulation

Once the database has been generated, switch to the Simulation mode by selecting the button above the object tree. Click on the action label to open the Run Options dialog as shown in Fig. 3DSPL1.26.. Use the default Continue Run option to select “Continue from the last step ” option and then select the Simulation mode as Interactive and click on button to run the simulation.

Run Simulation Window

Monitor the progress of the simulation by looking at the Simulation Message and Simulation Log tab, making sure that the option is checked. User can view the Spinning process as the simulation proceeds to the specified stopping criteria from Simulation graphics.