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7/24/2019 Rathmann_4th ICFG Workshop
1/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_1.ppt PtU, Rathmann
Development of a TechnologicalProcessor for 3D-FEA of
Rotary Swaging Processes
T. Rathmann
Institute for Production Engineering and Forming Machines
Darmstadt University of Technology, Germany
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P.Groche
Shanghai
23 28 May 2004
4th ICFG Workshop on Process Simulation
in the Metal Forming Industry
7/24/2019 Rathmann_4th ICFG Workshop
2/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_2.ppt PtU, Rathmann
Outline
Overview of the rotary swaging process
Experimental Verification
Technological Processor
Process-Simulation
7/24/2019 Rathmann_4th ICFG Workshop
3/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_3.ppt PtU, Rathmann
Introduction - Rotary Swaging
Rotary Swaging is a very efficient cold forming process for forming tubes and bars
Die segments arranged opposite to one another apply radial forces in rapid
succession.
ComponentsPrinciple
source: Felss
7/24/2019 Rathmann_4th ICFG Workshop
4/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_4.ppt PtU, Rathmann
Typical Components
Drive shaft
Hinge shaft
source: Felss
source: Felss
Gearshaft
source: HMP
Homokinetic joint
source: HMP
Rotary Swaging an efficient
cold forming process for forming
tubes and bars
7/24/2019 Rathmann_4th ICFG Workshop
5/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_5.ppt PtU, Rathmann
Rotary Swaging Process principle
Presentation as a sequence
7/24/2019 Rathmann_4th ICFG Workshop
6/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_6.ppt PtU, Rathmann
Process Variations
Infeed-swaging Recess-swaging
without
mandrel
withmandrel
7/24/2019 Rathmann_4th ICFG Workshop
7/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_7.ppt PtU, Rathmann
Problems and Objectives
The process planning has a crucial influence on the economic efficiency of the
process
Planning of stages
Die construction
Setup and adjustment
Die changes (possibly)
Process planning
Based on the knowledge of the staff members
Loss of knowledge if staff leaves employment
Common
Problems
knowledge
7/24/2019 Rathmann_4th ICFG Workshop
8/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_8.ppt PtU, Rathmann
Problems and Objectives
Geometric changes in components cause long try-out-times
Lay-out of rotary swaging machines and equipment is difficult
Increasing requirements concerning quality and accuracy (Net-Shape-Forming)
Complex interrelationships on process defining parameters
Analysis of the rotary swaging process by FEA
Simplif ication of the use of FEA by a technological
processor (as interface)
OBJECTIVES
Technological
Problems
7/24/2019 Rathmann_4th ICFG Workshop
9/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_9.ppt PtU, Rathmann
Postulated Process Planning
Drawing of
workpiece
Toolconstruction
Process Planning assisted by FEA
OK?Yes
NOK(up to now)
Try-Out
New parameters
Technological Processor
Modelling
Simulation
Analysis of the resul ts
7/24/2019 Rathmann_4th ICFG Workshop
10/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_10.ppt PtU, Rathmann
ProcessProcess--SimulationSimulation
7/24/2019 Rathmann_4th ICFG Workshop
11/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_11.ppt PtU, Rathmann
FEA-sequence up to now
MSC.Marc
Mentat
MSC.Marc
MSC.Marc
Mentat
Subroutine
FE-Knowledges required in
all steps
THE MARC SYSTEM
Preprocessing 80160 h
Time requirements
1
Steps
START
Analysis 5-500 h2
Postprocessing 5 h3END
7/24/2019 Rathmann_4th ICFG Workshop
12/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_12.ppt PtU, Rathmann
Problems of simulation of rotary swaging processes
3D3D--ModellingModelling High element numbersHigh element numbers
Representation of complex tool kinematicsRepresentation of complex tool kinematics
Contact changes in a high frequencyContact changes in a high frequency
High numbers of iterationsHigh numbers of iterations
Convergence
Computing time
Particularities concerning the simulation of rotary swaging processes
Incremental forming operation with 100 to 300 cycles
Tool-separation in every cycle
3D-Modelling required
rdie > rwp
work-
piece
die
problems
7/24/2019 Rathmann_4th ICFG Workshop
13/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_13.ppt PtU, Rathmann
Design of the Rotary swaging FEA-model
Representation of the tools by Rigid Bodies
Representation of the workpiece with 8-node
isoparametric 3D hexahedrons
Realisation of the relative movement between
die and workpiece only by the tools
No rigid body movement of the workpiece
Simplified evaluation
Easier implementation of analysis modules in the
technological processor
Advantages
7/24/2019 Rathmann_4th ICFG Workshop
14/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_14.ppt PtU, Rathmann
Use of cyclic symmetry
Possibility to reduce computing time (saving of time ~ )
Corresponding results (difference < 0,04%)
4-fold segmented tools Quarter-model
Reducing element numbers
7/24/2019 Rathmann_4th ICFG Workshop
15/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_15.ppt PtU, Rathmann
Examination of convergence
Maximalkraft
0
100
200
300
400
500
600
700
2D Grob 2D Mittel 2D Fein 3D Grob 3D Mittel 3D Fein Experiment
Netz
Radialkraft[kN]
2D 3D Exp.
Influence of spatial discretisationMax. radial force Frad
Representation of die movement
Objective: Reduction of element- and increment numbers
T
TDC
BDC
grid
radialfo
rce[kN]
7/24/2019 Rathmann_4th ICFG Workshop
16/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_16.ppt PtU, Rathmann
FE-Analysis
Adjustable Process parameters of machinery
Stroking frequency fsw
Rotational speed of external/internal rotor ne/ni
Axial rate of feed vax (Infeed swaging)
Radial rate of feed vrad (Recess swaging)
Rate of feed + Stroking frequency fsw Feed per pass vx,P
Rotational speed ni + Stroking frequency fsw Angle of rotation per pass P
Technological quantities
7/24/2019 Rathmann_4th ICFG Workshop
17/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_17.ppt PtU, Rathmann
Influence of the technological quantities
Einfluss des Drehwinkels pr o Hub
ESoD; v rad/Hub=0,0074=konst.
0
20
40
60
80
100
120
2,4 3,36 4,8 5,6 9,06 13,2 18,85 22Drehwinkel pro Hub []
Kraft[kN]
Fradmax [kN]
Faxmax [kN]
Einfluss des Axialvorschubes
VSoD (Drehwin kel pro Hub = 12 = kon st.)
0
20
40
60
80
100
120
140
0,012 0,017 0,028 0,048 0,091 0,167 0,278
Axialvor schu b pro Hub [ mm]
Kraft[kN]
Fradmax [kN]
Faxmax [kN]
0 10 20 30 40 50 60Weg [mm]
0
25000
50000
75000
100000
125000
150000
Frad[N]
0 10 20 30 40 50 60
Weg [mm]
0
2500
5000
7500
10000
12500
15000
Fax[N]
T:\Rundkneten\Vorschub\180703\5\fort.25.
Knetfrequenz: 30 [Hz]
3D Simulation
Kraftverlauf beim Vorschubrundkneten
Vorschubgeschwindigkeit: 0.05 [m/min]
max. Radialkraft : 126.1 [kN]
max. Axialkraft: 7.1 [kN]
Drehwinkel pro Hub: 13.6 []
Axialvorschub pro Hub: 0.03 [mm] Gittertyp: G2
Drehvorschub: 68 [1/min]
Maschinendaten Technologische Gren
HSS-Diskretisierung: 7 [Inc/Hub]
ohne Dorn
Simulationsspez. Angaben
Evaluation by comparing the maximum
occuring axial and radial forces
Force progression(Feed swaging without mandrel)
max. radial force: 126,1 kN
max. axial force: 7,1 kN
Influence of angle of rotation per passRSwoM; vrad/pass=0,07=const.
Influence of axial rate of feed per passFSwoM; P = 12 = const.
Angle of rotation per pass []
Axial feed per pass [mm]
Force
[kN]
Force[kN]
Swaging Frequency: 30 Hz
Axial rate of feed: 0,164 m/min
Rotating speed: 60 1/min
Process Parameters
Angle of rotation per pass: 12
Axial feed per pass: 0,09 mm
Technological Quantities
Increments per pass: 7
Grid-type: G2
FE-specific quantities
path [mm]
path [mm]
7/24/2019 Rathmann_4th ICFG Workshop
18/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_18.ppt PtU, Rathmann
0 10 20 30 40 50 60 70 80Lnge [mm]
9
10
11
12
13
14
15
16
R
adius[mm]
3
3.1
3.2
3.3
3.4
3.5
Wa
ndstrke[mm
]
T:\Rundkneten\Vorschub\040503\3\okr_dispyz.
Knetfrequenz: 30 [Hz]
3D Simulation
Wandstrkeverlauf beim Vorschubrundkneten
Vorschubgeschwindigkeit: 0.1638 [m/min]
Drehwinkel pro Hub: 12.00 []
Axialvorschub pro Hub: 0.09 [mm] Gittertyp: G2
Drehvorschub: 60 [1/min]
Maschinendaten Technologische Gren
HSS-Diskretisierung: 7 [Inc/Hub]
ohne Dorn
Simulationsspez. Angaben
Influence of the technological quantities
Evaluation by comparing the maximum
evaluated wall thickness (in the zone of
calibration) Einfluss des Drehwinkels pro HubESoD; v rad /Hub = 0,0074mm = konst.
3,24
3,26
3,28
3,3
3,32
3,34
2,4 3,36 4,8 5,6 9,06 13,2 18,85 22
Drehwinkel pro Hub []
max.
Wandstrkeim
Kalibrierereich[mm]
Einfluss des Axialvorschubes
VSoD (Drehwinkel pr o Hub = 12 = kons t.)
3,26
3,28
3,3
3,32
3,34
3,36
3,38
0,012 0,017 0,028 0,048 0,091 0,167 0,278
Axialvor sc hub p ro Hub [mm]
max.
Wand
strkeim
Kalibrierbereich[mm]
Course of wall thickness(Feed swaging without mandrel)
Influence of angle of rotation per passRSwoM; vrad/pass=0,07=const.
Influence of axial rate of feed per passFSwoM; P = 12 = const .
Angle of rotation per pass []
Axial rate of feed per pass [mm]
M
ax.wallthickness[mm]
Max.wallthickness[mm]
Swaging Frequency: 30 Hz
Axial rate of feed: 0,164 m/minRotating speed: 60 1/min
Process Parameters
Angle of rotation per pass: 12
Axial feed per pass: 0,09 mm
Technological Quantities
Increments per pass: 7
Grid-type: G2
FE-specific quantities
wallthickn
ess[mm]
path [mm]
7/24/2019 Rathmann_4th ICFG Workshop
19/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_19.ppt PtU, Rathmann
ExperimentExperimentaal Verificationl Verification
7/24/2019 Rathmann_4th ICFG Workshop
20/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_20.ppt PtU, Rathmann
Possibilities of Verification
S
I
MU
L
AT
I
ON
E
X
PE
R
IM
E
NT
Grain structure
Geometry
Force-measurement
0 5 10 15 20 25Zeit [s]
-2.5
0
2.5
5
7.5
10
Fax[kN]
0 5 10 15 20 25Zeit [s]
-25
0
25
50
75
100
Frad[kN]
Dateiname: V7_1.dat
Knetfrequenz (IST): 33 HzWerkstoff: 16 MnCr5 (1.7131)
Kraftverlauf beim Einstechrundkneten ohne Dorn
Abmessungen (L/D/s)[mm] : 330/30/3 Abtastrate: 3 kHz
Drehzahl Knetwelle : 110 1/minBemerkung: : -
Micro hardness
Plastic strain
7/24/2019 Rathmann_4th ICFG Workshop
21/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_21.ppt PtU, Rathmann
Metrology
Measurement of radial forces
Base jaw with integrated
force transducers
Front plate with adapted
telemetrical transmitter
Wireless transmission required
Telemetry
(rotating swaging shaft)
High sampling rates due to high swaging
frequencies (100 ... 300 measurements/pass)
Swaging shaft
Outer rotor
7/24/2019 Rathmann_4th ICFG Workshop
22/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_22.ppt PtU, Rathmann
Transmission of signals by wire
Metrology
Measurement of axial forces
force transducer
clamping unit
7/24/2019 Rathmann_4th ICFG Workshop
23/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_23.ppt PtU, Rathmann
0 5 10 15 20 25Zeit [s]
-2.5
0
2.5
5
7.5
10
Fax
[kN]
0 5 10 15 20 25Zeit [s]
-25
0
25
50
75
100
Fra
d[kN]
Dateiname: V7_1.dat
Knetfrequenz (IST): 33 HzWerkstoff: 16 MnCr5 (1.7131)
Kraftverlauf beim Einstechrundkneten ohne Dorn
Abmessungen (L/D/s)[mm] : 330/30/3 Abtastrate: 3 kHz
Drehzahl Knetwelle : 110 1/minBemerkung: : -
Results of measurements
Force progression (Recess swaging without mandrel)
Material: 16MnCr5
Dimensions: (D/L/Wt)[mm] 330/30/3
Stroking frequency (actual): 33 Hz
Sampling rate: 3 kHz
Swaging shaft: 110 rpm
time
time
Radial speed rate (20 mm/min)3s
calibration
20.4 20.425 20.45 20.475Zeit [s]
0
10
20
30
40
50
60
F_rad[kN]
Dateiname: V1_2_a.dat
Knetfrequenz (IST): 33 HzWerkstoff: 16 MnCr5 (1.7131)
Einzelschlagdarstellung F_rad
Abmessungen (L/D/s)[mm] : 330/30/3 Abtastrate: 3 kHz
Drehzahl Knetwelle : 28 1/minBemerkung: : -
fsw
Resolution of single strokes Frad
7/24/2019 Rathmann_4th ICFG Workshop
24/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_24.ppt PtU, Rathmann
TechnologicalTechnological ProcessorProcessor
7/24/2019 Rathmann_4th ICFG Workshop
25/39
Produktionstechnik und Umformmaschinen
Technische Universitt DarmstadtProf. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_25.ppt PtU, Rathmann
Technological Processor (TP)
To allow 3D-FEA of rotary swaging processes
for normal users without FE-knowledges
To evaluate and represent the results:- Forces
- Geometric parameters (diameter, elongation, course of wall thickness)
- Parameters of forming technology (stress, strain)
To simplify the input of all necessary input data:
- Process parameters
- Tool parameters- Semi finished product data
To carry out the simulation in background
What are the intentions?
Main objective:
7/24/2019 Rathmann_4th ICFG Workshop
26/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_26.ppt PtU, Rathmann
Structure of the Technological Processor
data base
START
technological
data
CAD-system
geometrical
data
FE-
program
input file
output/ result file
yes
OK?
END
no
Iterative Optimizer
PreprocessorCompiler for input file
PostprocessorEvaluation and representation
of the results
Technological Processor
7/24/2019 Rathmann_4th ICFG Workshop
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Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_27.ppt PtU, Rathmann
Programming-layout of the TP
Parameter entry
Compiling and editing of
routines
procedures and auto sequences
Automatic modelling
FE-Program
MARC/MENTAT
Programming languages:
Visual Basic (VB)
Visual Basic for
Applications (VBA)
7/24/2019 Rathmann_4th ICFG Workshop
28/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_28.ppt PtU, Rathmann
Entry masks
Selection of the process variant
Input of process-parameters
7/24/2019 Rathmann_4th ICFG Workshop
29/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_29.ppt PtU, Rathmann
Entry masks
Input of tool parameters
7/24/2019 Rathmann_4th ICFG Workshop
30/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_30.ppt PtU, Rathmann
Entry masks
Input of workpiece parameters
Initial position as well as workpiece
length will be calculated automatically.This yields to minimized element
numbers.
A manual input is also possible.
7/24/2019 Rathmann_4th ICFG Workshop
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Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_31.ppt PtU, Rathmann
Special entry masks
FEA-specific
details
Standard-grid
coarse middle smooth
7/24/2019 Rathmann_4th ICFG Workshop
32/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_32.ppt PtU, Rathmann
Single stroke discretisation
Special entry masks
7/24/2019 Rathmann_4th ICFG Workshop
33/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_33.ppt PtU, Rathmann
these masks are provided for the advanced user
they normally are skipped
Storage of the results
Remark to the special entry masks
Reduction of the amount of data
(storage-saving).
Not for all increments a result file is
written.
Special entry masks
7/24/2019 Rathmann_4th ICFG Workshop
34/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_34.ppt PtU, Rathmann
Evaluation masks
Evaluation of the course of forces
0 10 20 30 40 50 60Weg [mm]
0
25000
50000
75000
100000
125000
150000
Frad[N]
0 10 20 30 40 50 60Weg [mm]
0
2500
5000
7500
10000
12500
15000
Fax[N]
T:\Rundkneten\Vorschub\180703\5\fort.25.
Knetfrequenz: 30 [Hz]
3D Simulation
Kraftverlauf beim Vorschubrundkneten
Vorschubgeschwindigkeit: 0.05 [m/min]
max. Radialkraft: 126.1 [kN]
max. Axialkraft: 7.1 [kN]
Drehwinkel pro Hub: 13.6 []Axialvorschub pro Hub: 0.03 [mm] Gittertyp: G2
Drehvorschub: 68 [1/min]
Maschinendaten Technologische Gren
HSS-Diskretisierung: 7 [Inc/Hub]
ohne Dorn
Simulationsspez. Angaben
Force progression(Feed swaging without mandrel)
max. radial force: 126,1 kN
max. axial force: 7,1 kN
Swaging Frequency: 30 HzAxial rate of feed: 0,164 m/min
Rotating speed: 60 1/min
Process Parameters
Angle of rotation per pass: 12Axial feed per pass: 0,09 mm
Technological Quantities
Increments per pass: 7Grid-type: G2
FE-specific quantities
path [mm]
path [mm]
Choose the file to be evaluated X
Save as: X
7/24/2019 Rathmann_4th ICFG Workshop
35/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_35.ppt PtU, Rathmann
Evaluation masks
Evaluation of the course of wallthicknessChoose the file to be evaluated X
Course of wall thickness(Feed swaging with mandrel; D=18.5mm)
Swaging Frequency: 30 Hz
Axial rate of feed: 0,164 m/min
Rotating speed: 60 1/min
Process Parameters
Angle of rotation per pass: 12
Axial feed per pass: 0,09 mm
Technological Quantities
Increments per pass: 7
Grid-type: G2
wa
llthickness[mm]
path [mm]
Save as: XFE-specific quantities
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36/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_36.ppt PtU, Rathmann
Evaluation masks
Representation of parameters of forming technology
.
Knetfrequenz: 30 [Hz]
Equivalent von Mises Stress
Vorschubrundkneten ohne Dorn
Vorschubgeschwindigkeit: 0.5 [m/min]
Max. Main Stress
Drehwinkel pro Hub: 13.8 []
Axialvorschub pro Hub: 0.26 [mm] Gittertyp:G2
Drehvorschub: 68 [1/min]
Maschinendaten Technologische Gren
HSS-Diskretisierung: 7 [Inc/Hub]
Simulationsspez. Angaben
Feed swaging without mandrel
Swaging Frequency: 30 Hz
Axial rate of feed: 0,164 m/min
Rotating speed: 60 1/min
Process Parameters
Angle of rotation per pass: 12
Axial feed per pass: 0,09 mm
Technological Quantities
Increments per pass: 7
Grid-type: G2
FE-specific quantities
Save as: X
C i FEA ith/ ith t t h l i l
7/24/2019 Rathmann_4th ICFG Workshop
37/39
Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_37.ppt PtU, Rathmann
Comparison FEA with/without technological processor
MSC.Marc
Mentat
MSC.Marc
MSC.Marc
Mentat
Subroutines
Conventional execution
FE-Knowledges required in all
steps
Technological processor
Input via Entry-
masks
MSC.Marc
Automated
evaluation via
Entry masks
Hardly no FE-
Knowledge required
Pre-
processing 5 min120 h
STARTSTART
250 h 60 hSimulation
END
Post-
processing10 min
5 hEND
Time need reduced considerably !
S
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Produktionstechnik und UmformmaschinenTechnische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_38.ppt PtU, Rathmann
Summary
Reduction of the development timeReduction of the development time
Improv
edmod
elling
R
educ
edcom
puting
time
SimulationSimulation
Improved
availabilityandadministration
oftheknowledgeoftheproc
ess
Knowledge baseKnowledge baseTechnological processorTechnological processor
Examination of the rotary swaging process with thehelp of 3D-FEA
Simplified use and integration of FEA in the process
planning
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Thank you for your attention!