Diestress analysis 3D

Lab2:
Problem Summary:
This lab will demonstrate how to run a die stress analysis with shrink fit in die stress
wizard. When the stress analysis is being done on die assemblies where there is
interaction between the tools, more than one step is typically needed for the die stack to
come to a state of equilibrium under the applied load.
In a typical die stress simulation, the workpiece is removed and the forces exerted onto
the dies by the workpiece are interpolated onto the tools. In this lab, a shrink fit is
modeled.

Pre Processing:
Start a new Die stress analysis Wizard problem with problem ID "shrinkfit". You can do
so by clicking the New problem button and choose Die stress analysis.
Alternatively, you can right click on the directory tree to create an empty directory and
click Diestress analysis on the right side of the main window.

Give operation Name as Diestress. Click Next to go to deformation database page

Click Next to go to deformation database page. In the deformation database page, browse
the deformation database and select the step, for which the diestress analysis to be done.
We would like to perform a die stress analysis on the tools at the end of the first blow of
the Spike simulation (Labs 5 8 in 3D labs). So browse Spike.DB and select Step 90
which corresponds to the end of Blow 1.

After selecting the step, click next to proceed to the object selection page. In this object
selection page, select the objects for which diestress analysis to be done. For now select
both the dies and click next to go to extra objects page.

Once we click the Next button it will ask for default symmetry boundary conditions
assignment. Click Yes for when it ask for default boundary conditions.

Two supports will be added to the simulation which will interact with the top and bottom
dies. So in the extra objects page, add two any more objects. Enter 2 for number of extra
die components.

Click next to go to simulation mode page. Here we can select either Non isothermal mode
or Isothermal mode. Now select Isothermal mode. Click Next to go to object data page.

In the top die object data page by default the object type will be selected as elastic. So
keep all the default values as it is and click Next to go to geometry page.

As already we defined the geometry there is no need to define it again. So click Next to
go to mesh generation page. Here the user can define mesh by giving the size ratio and
number of elements for elastic die. But for this case as already we have defined the mesh
previously (in the Spike.db). So no need of mesh generation again. Click next to go to
force interpolation page.
In the force interpolation page the force of the workpiece will be interpolated on to the
dies. Use an Error Tolerance of 0.1 (should be approximately equal to an element size in
the workpiece) and click on Interpolate force active button.

A summary window should appear, showing the forces on the billet and the forces that
were interpolated to the die. These forces will generally not be exactly equal. The Error
tolerance controls this to some degree. Putting in a higher tolerance will interpolate the
forces from more of the billets surface nodes, increasing the forces interpolated to the
dies. As long as the forces for the Workpiece and the Die are pretty close, the
interpolation is considered successful.

If you make the object transparent (by clicking the

icon while the Top Die is
highlighted in the Object Tree) the interpolated forces can be seen.

Click Next to go to deformation BCC page. As we have already select default boundary
conditions while selecting the dies, the symmetry boundary conditions are active in BCC
page. Now we need to fix the top nodes of the die in Z direction to prevent the die from
flying off when the forces are applied. To do this Select the top nodes of the dies and fix
the velocity in Z direction as shown in the figure below.

Click Next to go to die material page. Here user can assign a material for die from the
material library or from a file. And user has an option to create a new material, edit a
material or delete a material. For this case H13 material is already assigned so no need to
assign a new material.
Click Next to enter into bottom die object data definition page. In the bottom die object
data page by default the object type will be selected as elastic. So keep all the default
values as it is and click Next to go to geometry page.

As already we defined the geometry there is no need to define it again. So click Next to
go to mesh generation page. Here the user can define mesh by giving the size ratio and
number of elements for elastic die. But for this case as already we have defined the mesh
previously (in the Spike.db). So no need of mesh generation again. Click next to go to
force interpolation page.
In the force interpolation page the force of the workpiece will be interpolated on to the
dies. Use an Error Tolerance of 0.1 (should be approximately equal to an element size in
the workpiece) and click on Interpolate force active button.

A summary window should appear, showing the forces on the billet and the forces that
were interpolated to the die.

Click Next to go to deformation BCC page. As we have already select default boundary
conditions while selecting the dies, the symmetry boundary conditions are active in BCC
page. Now we need to fix the nodes on the bottom side of the die in Z direction to prevent
the die from flying off when the forces are applied. To do this Select the nodes on the
bottom side of the dies and fix the velocity in Z direction as shown in the figure below.

Click Next to go to the material page. Here H-13 material is already defined.
Click Next to enter extra object 1 page. Change the name of Extra Die 1 to Upper
Support. Keep the object type as Elastic and click Next to enter the geometry
definition page. Import UpperSupport.STL from C:\DEFORM3D\V6_1\LABS.
Click Next to Mesh generation page Mesh the support using default mesh settings. Click
Next to enter Force interpolation page. Dont interpolate any force on the upper support.
When we click Next the die stress analysis wizard will ask whether to interpolate force or
not. Click No when it asked for it.

In the Deformation BCC page specify Symmetry plane boundary conditions on the two
symmetry surfaces of the Upper Support. Apply a Vz = 0 Velocity boundary condition on
the top surface so that the top surface cannot move in the Z-direction.
This object gets a shrink fit applied to it, so select the Shrink Fit boundary condition.
Shrink fit is defined radially, so an axis and a point need to be defined. For this analysis,
(0, 0, 0) is the point at the center of the dies, and the Z axis is the axis of the objects. If
the shrink fit is applied to the inner object, the value should be negative. If the shrink fit
is applied to the outer object then the value should be positive. Since we are applying the
shrink to the outer object, use a value of 0.004 for the Interference.
Once the above circles parameters have been set, select the inner surface of the support
and then use
to apply the shrink fit. When prompted if you want to move the
coordinates of the nodes, click NO.

Assign H-13 as the material of this support as explained above.

Click Next to enter extra object 2 page. Change the name of Extra Die 1 to Lower
Support. Keep the object type as Elastic and click Next to enter the geometry
definition page. Import LowerSupport.STL from C:\DEFORM3D\V6_1\LABS.
Click Next to Mesh generation page Mesh the support using default mesh settings. Click
Next to enter Force interpolation page. Dont interpolate any force on the upper support.
When we click Next the die stress analysis wizard will ask whether to interpolate force or
not. Click No when it asked for it.

In the Deformation BCC page specify Symmetry plane boundary conditions on the two
symmetry surfaces of the Upper Support. Apply a Vz = 0 Velocity boundary condition on the
bottom surface so that the bottom surface cannot move in the Z-direction.

Assign H13 die material as we did for Upper support.

Click Next to enter the Positioning page. All the objects are in position for this case. So
keep it as it is and click Next to enter the Inter-Object Contact page. Here inter object
contact relations can be defined for different pairs.
Relationships need to be defined between the Top Die and the Upper Support and also
the Bottom Die and the Lower Support. So select Top die Upper support pair and keep
Slave- Master type , with a friction of 0.3 and with a suitable contact tolerance generate
the contact between Top die Upper support.
Define the same contact relation between Bottom die and Lower support as explained
above. Keep Lower support as Master and Bottom die as Slave. Generate the contact.

By Clicking Next we will enter into Simulation controls page.

Since there will be interaction between the tooling, more than one step should be
modeled so that the parts can come to equilibrium. Set the Starting Step Number to -1,
the Number of Simulation Steps to 6 and the Step Increment to Save to 1 and Max.
elapsed process tome per step as 1. Keep the default Conjugate- Gradient solver and click
Next to enter the database generation page.

Check the database and Generate database. Once the database is generated Click Finish to
close the die stress analysis wizard preprocessor.

Running the simulation and Post Processing:

Switch to Simulate panel and start the simulation by clicking Run simulation. Once the
simulation is over switch over to Post panel to view the results of simulation.
Using the State Variables, plot Effective stress and Max Principal stress, two of the most
important variables in die stress simulations.