8.

SPIKE FORGING - DIE CHANGE AND BLOW 2

8.1. Introduction
8.2. Opening a Previous Simulation
8.3. Changing Top Die for Blow 2
8.4. Defining New Top Die Boundary Conditions
8.5. Positioning the Top Die
8.6. Redefining Inter-Object Contact
8.7. Setting Simulation Controls
8.8. Saving the Problem and Running the Simulation
8.9. Post-Processing

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8. Spike Forging - Die Change and Blow 2

8.1. Introduction
The first forging blow has been simulated and it is now time to model the second blow which uses
a different top die. The new top die geometry will be imported and the second forging operation
will be set up.

8.2. Opening a Previous Simulation

The DEFORM-3D MAIN window should already be open. With the Spike.DB file highlighted in
the file list, click
blow, Step 90, and click

to open the Pre-processor. Select the end of the first forging

.

8.3. Changing Top Die for Blow 2

Both the geometry and mesh of the top die have to be changed. Highlight the Top Die in
the Object Tree, click

and delete the mesh by clicking

. The

original Top Die mesh is now gone but the old geometry still remains. Click
and
import the geometry Spike_TopDie2.STL. The new top die geometry will be shown in
the DISPLAY window. Mesh the new die using the default mesh settings by clicking
and then

. Click the

icon in the General page, to define a

button and select the material 'H-13'

material for the new top die. Click the
from the Die-material Category. Assign this material to the Top die.

8.4. Defining New Top Die Boundary Conditions

Since the top die has been changed, both the heat transfer and deformation boundary conditions
need to be reapplied for the new geometry.
Deformation: click
, select the Symmetric Surface tab, and select both symmetry planes
so that they are highlighted green.

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Heat Transfer: click

and select Heat Exchange with Environment. Select all

surfaces of the top die except the symmetry planes and then hit
condition.

to apply the boundary

8.5. Positioning the Top Die

Click

and select interference. Change the Positioning Object to the Top Die and the Reference

to the Billet. Change the Approach Direction to -Z and then click

positioning, the following message will appear:

Click

. After

to initialize (delete) the contact between the Billet and the old Top Die.

8.6. Redefining Inter-Object Contact

Since the geometry of the Top Die has been changed, contact between it and the Billet needs to be
regenerated. Click
tolerance and then click

to open the INTER-OBJECT window, click

to set a suitable contact

8.7. Setting Simulation Controls

to enter SIMULATION CONTROLS. Change the Operation Name to
Click
Forging Blow 2 and the Operation Number to 4.

We want the Top Die to travel 0.25" during this second forging blow. Click
and set the
Number of Simulation Steps to 10. Leave all of the other stepping parameters the same so that 10
steps will be run at 0.025in/step.

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8.8. Saving the Problem and Running the Simulation

Select File Save as and save the data as Spike_Blow2.KEY. Next, click the
the DATABASE GENERATION window. Click
warning. Click

icon to open

. Ignore the Volume Compensation

After the database is generated, to the MAIN window and start the simulation by clicking
Monitor the progress of the simulation by looking at the Message file.

8.9. Post-Processing
When the simulation has finished, click on
the steps.

. Click

and view

of

Play through the steps, focusing especially on the steps for the second forging blow, Steps-90 to
100. Use the
button to view how the contact evolves through the simulation. Also, investigate
temperature, effective strain and load vs. stroke behavior.

When finished, click

to return to the MAIN window.

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