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Q1 / 2019 www.afdex.com, mfrc@afdex.com
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Contents Table 1.2 Plan of adding new functions or conducting 1.2.3 Grain size prediction and experimental
improvements for AFDEX_V19
verification of hot forged bearing part
1. AFDEX_V18 and AFDEX_V19 New functions or improvements
1.1 Summary of improved and new functions The grain size was predicted during hot forging and the
1.2 Main features of AFDEX_V18 -Anisotropy of material
2D -Multi-function of blanking holding die or binder validity of the results was verified. The material constants
1.3 New features of AFDEX_V19 were obtained using AFDEX's unique optimization
or -Treatment of non-separation boundaries of multi-
3D body problem technique for the single stage upsetting process of the
2. Main events -Die less forming (Problem type 29)
2.1 Summary of 2018 three-stage process. When compared with the
2.2 First quarter of 2019 experimental results, it is concluded that the error is about
10%, which can be lowered using optimized material
1.2 Main features of AFDEX_V18 parameters.
1. AFDEX_V18 and AFDEX_V19 1.2.1 Elastoplastic finite element analysis of
riveting process in aircrafts
1.1 Summary of improved and new functions
The experimental results (Amarendra.A, GIT, Ph.D.
AFDEX_V18R01 was released for trial in April 2018. thesis, 2006, experiment and ABAQUS comparison)
AFDEX_V18R02 was finally updated in September 2018
after verification from domestic and international experts.
were compared with our elastoplastic finite element A
analysis of the riveting process of an aircraft using 2D
The main functions are listed in Table 1.1 and some of multi-body function. As shown in the figure 1.1, the
them are detailed in Section 1.2. experimental results and the analytical results closely
match with each other. B
Table 1.1 New functions or improvements of AFDEX_V18
Functions or improvements
-Function for skin element generation .n
-Function for calculating flow stress depending on
compressive or tensile strain Fig. 1.3 Determination of grain size
-Quantification of grain flow lines
-Multi-body simulation for isothermal analysis 1.2.4 Quantification and visualization of metal
-Recursive motion of dies (Loading and unloading) flow lines
-Sophisticated material models
-Microstructural evolution prediction
-Heat treatment and carburization simulation Quantification of the flow lines is very important. This
-Local heating of material technique has been developed on the basis of AFDEX's
-Improved structural analysis of assembled dies unique metal flow line visualization capabilities, and 2D
-Improved complete simulation features have already been introduced. Recently, three-
-3D local remeshing (a) Deformation history dimensional functions have been added. This function
-Solution of computationally large process like allows the evaluation of the quality of the metal flow lines
coining, etc.
by a numerical value, which is effective in arriving at an
-Spring back analysis
2D -Hammer open-die forging optimal process design and preventing mistakes. Fig.
and -New shearing, piercing, trimming and blanking 1.4(a) shows the decisive defect of the short-circuited
3D -Flow stress coupled with damage lines while forging a connecting rod, which can be hardly
-Removing a part of material at once observed from strain distribution in Fig. 1.4(b).
-Improved open-die forging
-Varying heat transfer coefficients
-Varying frictional condition
-Non-penetration die-gap treatment
-Two step Coulomb friction
-Supplying state variables at the final stroke at the
specified points
-Continuous prediction of grain(metal) flow lines in
2D/3D combined simulation
-Improved unloading prediction
-Penetration of material into dies allowed, one for
just allowance and the other for a kind of complete (b) Comparison of prediction and experimental results
analysis
-Simultaneous simulation of heat transfer and Fig. 1.1 Elastoplastic FE analysis of riveting process
structural analyses of assembled die in aircrafts
2D -Improved contact treatment after remeshing
1.2.2 Elastoplastic finite element analysis of ball-
-Improved spring-attached die bearing contact problems
-Improved function for imposing boundary
conditions The contact and local plastic deformation analysis of
-Layered mesh system of plate/sheet and pipe the ball bearing assemblies were carried out using the (a) Metal flow lines and overlapping index
-Function for stabilizing unstable material three-dimensional multi-body elastoplastic finite element
-Improved acceleration/deceleration function
analysis function.
-Contact analysis of two moving materials including
a pair of bevel gears
3D
-Removing tail of material
-Improved multi-contact node treatment
-Problem type 1 for special problems of all fixed die
cases
-Function for imposing boundary condition in the
longitudinal direction
-Improved contact treatment at the interface of two (b) Effective strain distribution
dies
Fig. 1.4 Quantification of metal flow lines
The release of AFDEX_V19R01/beta is planned to be
released for APA test purpose in January 2019. Its key
1.2.5 Solving computationally large problems
functions are listed in Table 1.1 and some of them are
(a) Mesh (b) Time= 0.09s (c) Time = 0.12s The ability to solve large-scale problems has been
described in detail in Section 1.3. Some of the new
improved to expand the various capabilities and analysis
features have been provided through AFDEX_V18 with Fig. 1.2 Elastoplastic structural analysis
functions to multi-body processes in recent years. Fig.1.5
improvements, but they will be officially available in of ball bearing assembly
shows the results of the analysis of the crankshaft hot
AFDEX_V19.
forging process and 500,000 tetrahedral elements were 1.3 Some examples of AFDEX_V19 Figure 1.10. shows an example of optimal design to
used. We plan to progressively improve functions for prevent the local sinking of grain flow lines. In
computationally expensive problems according to 1.3.1 Application of optimal design considering consideration of the characteristics of local sinking of
demand from the users. grain flow lines, the objective function is defined using
grain flow lines
the grain flow density and overlapping index, which are
defined in two directions. In the objective function, the
Figure 1.8 shows an optimal design for the forging
Initial effective strain and maximum forming load are also given
process of a first-generation hub bearing's outer ring. The
weights and constraint equation is used to maintain the
objective function is the difference of grain flow line
gap of the flash unit constant.
function values calculated at two symmetric points.
Stage 1
Figure 1.8 compares the grain flow lines of the initial and
optimal designs. As shown in this figure, the grain flow
lines satisfying the up-down symmetry condition was
Cooling
obtained by performing optimal design without user
intervention (KSTP Fall Conference, Jeju Island,
2018.10.11).
Stage 2
Cooling
Stage 3
(b) FE Prediction
Left Right
(b) Experiment (b) Bird’s eye view
Fig. 1.16 Analysis result of trimming process
Fig. 1.14 Analysis of cold cutting process of bar and
comparison with experiment results 1.3.4 Remesh in 3D multi-body process analysis
Figure 1.15 shows the predictions of the piercing
(a) Effective strain predictions
process, and Figure 1.16 shows those of the trimming
process. Both examples used dense elements at the
cutting area, and the element quality was good enough at
the cut surface.
Figure 1.15 shows the piercing process in the thick
plate, where the cross section is visualized.
Figure 1.16 shows the trimming process in which
material separation occurs in most of the regions in a
short time, but trimmed shape near the corner of the
material showed very sharp edge. (KSTP Fall Conference,
Jeju Island, 2018.10.12).
30
150 http://blog.altair.co.kr/54694)
He presented the subject of 'optimal design of grain
100
flow lines in forging process for bearings using AFDEX
and HyperStudy ' in Manufacturing Session.
50
On the other hand, a lot of research and applications MFRC participated in the IMTEX 2018 exhibition held
have been made on the widely used flow stress models in Bengaluru, India for five days from January 25 to 30,
including Voce model, Hansel-Spittel model and 2018. IMTEX 2018 is an international exhibition held in
Johnson-Cook model. The problem is about the accuracies India and is a major event in the Indian metal forming
and generalities of these flow stress models and their industry. MFRC also held technical seminars and practice
applicability. sessions in Bengaluru, Pune and Delhi. Fig. 2.6 ATC 2018 Korea
2.1.6 EATC
Fig. 2.10 Toronto, Canada Fig. 2.13 GISPAM participants in MFCAE 2018
Recently, the number of users of AFDEX in North 2.1.9 GISPAM 2018 The 7th ASIAFORGE Meeting 2019 will be held
America has been increasing, and about 250 people visit in India this year on January 19,20 at
AFDEX homepage in North America every day. To meet GISPAM 2018 was held at Gyeongsang National
University for five weeks starting from July 16. It is an
Mahabalipuram. MFRC would be participating in
these North American interests, we held active marketing this event as a sponsor and our team looks forward
events and education and/or user-meeting events at the international educational event in which 25 distinguished
students from Mexico, 10 Korean university students and to interacting with the Asian forging community.
Altair's headquarters in Troy, Detroit, Toronto in Canada
and Mexico City, State of Mexico (UPVM) and Juarez 2 university students from Malaysia participate. All
Ciudad in Mexico around late October and early Mexican participants' budgets are supported by the State
November this year. of Mexico government.
GISPAM is the fifth international event of the year,
started by the government of the State of Mexico five
years ago, requesting AFDEX training for the best
scholarship students in the State of Mexico (within the top
5%)
The subjects that were lectured consisted of mechanics
Fig. 2.15 AFM 2019
with some fundamentals including mathematics, statics
and solid mechanics, engineering plasticity, finite element
method, CAD practice, AFDEX practice and creative
application, technical writing and presentation. All 2.2.2 The first version of V19
lectures are conducted in English. In addition, we The first version of V19 will be released in the early
provided students with useful training experiences by March. Early birds can use it at the end of January
visiting companies and experiencing traditional Korean of this year.
Fig. 2.9 Troy, Detroit culture.