rr manual all

109
S S H H A A P P E E - - R R R R User’s Manual Solutions for Highly Advanced Process Engineering SHAPE Co., Ltd. www.shape.co.kr

Upload: trandatjp

Post on 18-Nov-2014

63 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: RR Manual All

SSHHAAPPEE--RRRR User’s Manual

Solutions for

Highly

Advanced

Process

Engineering

SHAPE Co., Ltd. www.shape.co.kr

Page 2: RR Manual All

SSHHAAPPEE--RRRR

UUUssseeerrr’’’sss GGGuuuiiidddeee MMMaaannnuuuaaalll

Page 3: RR Manual All

olutions for ighly dvanced rocess ngineering

I. Introduction 1

S H A P E

I. Introduction I.1. Introduction of Ring Rolling Process

Ring rolling is a specialized form of rolling process for manufacturing seamless ring. On a typical ring rolling machine, a ring shaped blank is expanded to a desired final diameter and is formed to have a desired cross section by using two sets of rolls. The radial set of rolls controls the radial thickness of the ring, while the axial roll and an idle pressure roll (mandrel). By keeping the driving roll axis stationary, the pressure roll is driven radially toward the driving roll and the main deformation of the workpiece occurs in the radial gap leading to an increase of the ring diameter. The axial rolls are tapered in order to reduce the velocity difference between the surface of the rolls and the workpiece.

This process is widely used in many industrial fields. The advantages of ring rolling are short production time, uniform quality, closed tolerance, and considerable saving in material cost. Although the ring rolling process is similar to plate rolling, there are some significant differences that make it inappropriate to apply the analytical method of the conventional plate rolling process to ring rolling. First, work piece has a curvature and its radius change continuously. Second, diameters of the driving roll and the pressure roll are different. Third, pressure roll is idle and advanced to the driving roll side continuously. Forth, metal flow is three-dimensional. For these reason, designing of the ring rolling process has long been done only through experiments, experience.

I.2. Introduction of SHAPE-RR In 1990, The CEO and president of SHAPE, professor Nak-soo Kim developed the first full-3D FEM solver in

the world. He simulated plain and T-shape ring rolling process when he worked at ERC/NSM in the Ohio State University. “SHAPE-RR” program developed with the full 3D FEM solver. Furthermore, we improved the solver and add many functions for designing roll and pre-form (or blank) of ring rolling process. Optimize the quality of your final product already prior to manufacturing by using the first simulation solution for the ring rolling process. Until now there is no proper material flow simulation program which allow to analyze the whole three-dimensional ring rolling process with exact calculation. Now SHAPE show you an attractive ring rolling software. This software allows you to simulate and test the usability of a new set of rings on the screen and to modify it accordingly in case of too high inner material strain. The “virtual” ring rolling roll checks the function of the complete set of rolls in a sort of test run-a crucial advantage for the user.

In order to develop such complicated products, the designer has to identify possible sources of errors at a very

early stage, if possible before physically manufacturing the products, in order to integrate the necessary design

adaptations already in the pre-manufacturing phase. Don’t afraid about this new software usage. If you have a basic

ring rolling knowledge and a hand to click mouse, it must be a piece of cake. SHAPE-RR is for engineer yourself.

I.3. About This Manual

The goal of this manual is to help the users who are not used finite element method software to successfully

simulate a ring rolling process. All steps will be introduced step by step, so the user is guided through the entire

process. After having worked through this user’s manual, you will be able to do the analysis of ring rolling process

and feel the power of finite element method. To get a flexible manual quickly leading to the most important points

some symbols with following meaning have been introduced

Page 4: RR Manual All

olutions for ighly dvanced rocess ngineering

II. Basic Theory 1

S H A P E

II. Basic Theory

II.1. Velocity Field

The three-dimensional simulation of the ring rolling process is divided to two different procedures. One is to find the velocity field in the current configuration of workpiece(ring) and the other is to update the geometry of the workpiece according to the velocities found. The workpiece is represented numerically by a ‘mesh system’ which consists of ‘nodes’ and ‘elements’. The velocity field can be found by the rigid–plastic finite element method needs iterations to find converged velocities at nodes. Once the velocities are calculated for the given geometry and the boundary conditions, the mesh system can be rotated(of course, numerically!) accompanying its own shape changes. This numerical procedure is called ‘updating’ of the mesh system.

II.2. Mesh System

Two kinds of mesh systems are used for the simulation. Actual Mesh System(AMS) is a mesh system fixed to the workpiece. It stores every information on the material of the workpiece, e.g., geometry of the workpiece (coordinates of the nodal points), history of plastic deformation (total effective strain), etc. Spacial Mesh System(SMS) is a mesh system fixed in the space but changing its geometry according to that of the AMS. The SMS keeps providing velocity field for the given geometry by the finite element method. By increasing two kinds of mesh systems, unnecessary computations to take each node’s boundary changes into considerations in the normal rigid plastic FEM are avoided. SMS can be constructed with fine meshes in the main deforming zone and rough meshes in the understanding almost rigid zone. Hence it saves the computing time enormously.

Fine mesh in deforming zone Rough mesh in

rigid zone

( Actual Mesh System ) ( Spacial Mesh System )

Fig.II.1 Mesh system

Page 5: RR Manual All

olutions for ighly dvanced rocess ngineering

II. Basic Theory 2

S H A P E

II.3. Rigid Plastic Finite Element Method

II.3.1. Domain of workpiece

The configuration of a body occupies the space V at a given time t(see Fig. II.2). Velocity is prescribed on the surface Sv and traction is prescribed on the surface Sf. Total surface is composed of Sv and Sf. If the material points in the body follow the law of linear momentum conservation, we can apply so-called equations of motion to the particles. If the acceleration term and body force term are neglected compared to the stress gradient term, we obtain the following equations of equilibrium.

Equilibrium equation : 0=

j

ij

in V

II.3.2. Boundary conditions

The boundary conditions to the body V can be divided into two types.

Traction B.C. : on S∗== iijij ttnσ

f

Velocity B.C. : on S∗= ii vv

v

Numerically, traction B.C.’s are called to “suppressible” B.C.’s and velocity B.C.’s are called to “natural” or “essential” B.C.’s.

Fig.II.2 Boundary condition

Page 6: RR Manual All

olutions for ighly dvanced rocess ngineering

II. Basic Theory 3

S H A P E

II.3.3. Governing equations

The problems are limited to quasi-static and infinitesimal deformation based on the rigid-plastic approach in the

formulation. The inertial effects, body forces, and changes in geometry due to deformation are neglected. Then the velocity and stress fields satisfy the following conditions. (i) Equilibrium equations

0, =jijσ

(2.1)

(ii) Boundary conditions

TotalFUFijij

Uii SSSStnSvv

=+⎭⎬⎫

==

onon

σ (2.2)

(iii) Flow-rule (constitutive equations)

ijij σσεε ′=&

& 23

, (2.3)

where

21

)( 32 p

ijp

ijp εεε &&& =

and 2

1

)( 23

ijijσσσ ′′=.

(iv) Relationship of strain rate-velocity (compatibility equation)

)( ,,21

ijjiij vv +=ε& (2.4)

(v) Incompressibility

0=kkε& (2.5)

(vi) Flow stress

),,( Tεεσσ &= (2.6)

Page 7: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 4

S H A P E

III. Overview of SHAPE-RR

III.1. Simulation Procedure

III.1.1. Assuming contact

Actually exact contact is impossible in the finite element method. Within a scheduled margin of error, assuming roll and workpiece are contact.

III.1.2. Updating the AMS

The velocity of the AMS nodes is obtained by linearly interpolating those of the SMS nodes. From the

interpolated velocities, the displacements in the AMS during the time dt are calculated. In SHAPE-RR, to deal with a large time increment in a step, the angular velocity of a material point is always found as a linearly interpolated value from those of the SMS nodes. We can represent a material point of the workpiece, or AMS as P and neighboring special points, or SMS nodes as A and B.

Fig.III.1 Updating AMS

Page 8: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 5

S H A P E

III.1.3. Updating the SMS

The θ-direction of the position vector of the nodes in the SMS is fixed and the positions of nodes change only in the r- and z- directions. The nodes in the SMS are reconstructed based on the AMS of which geometry and material property are already updated from the velocity field in the SMS.

Fig.III.2 Flow chart

Each node in the SMS is interpolated from the nodes in the AMS. To relocate the nodes in the SMS, first, the neighboring nodes of the AMS should be found.

Page 9: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 6

S H A P E

III.1.4. Updating the ring center

As the process progresses, the radius of the ring increases, the position of the ring center changes. In order to determine the location of the ring center, the following three steps are used. Step1: Updating ring center by velocity field Step2: Adjusting ring center by the volume constancy Step3: Locating the geometry

III.1.5. Updating the rotating axles

SHAPE-RR transforms rectangular coordinates to get exact answer, because a ring is inclined (x, y, z coordinates → x, y’, z’ coordinates ). Rotating axles update and return 3.2.1

Page 10: RR Manual All

olutions for ighly dvanced rocess ngineering

7

S H A P E

III.2. Overview of SHAPE-RR Windows Menu bar: Consist of File, Pre-Process, Solution, Post-Process, Feature, Frame, Tool, View, Window, Help.

Icon Tool bar: Several icons are shown in this icon tool bar which use SHAPE-RR

Fig.III.3 SHAPE-RR Windows

Main Display Window: Results of workpiece are displayed in this window

• Workspace bar Information of whole passes and roll can be checked.

• Information bar Display information of selected points as a color

Workspace bar

Information bar

Output bar: The message from the solver is listed up while doing the simulation.

III. Overview of SHAPE-RR

Page 11: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 8

S H A P E

III.3. Setting Preference Setting preference of SHAPE-RR can be selected a command from the File pull-down menu.

Fig.III.4 Preference menu Setting preference consists of four folders such as basic, directories, window styles, and hardware summary.

Page 12: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 9

S H A P E

III.3.1. Basic

Basic offers several settings for SHAPE-RR. • Screen color: It is fixed as 32bit to the all situation when 17” monitor used.

• Rendering context color: It has variables that’s in monitor, so Screen Dependent is strongly recommended.

• Z(depth)-buffer: This option enable to express rich color.

• Enable double-buffer: This option increases analysis speed.

• Accelerated by a device driver: This option offers VGA acceleration.

Fig.III.5 Basic tab

Page 13: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 10

S H A P E

III.3.2. Directories

Directories preference enables to change directories which want to save. To change saving directories or location, click Browse.

Fig.III.5 Directories tab

If user wants to change directory, select directory where under the Temporary Working Directory. In there, select Browse to change directory.

Page 14: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 11

S H A P E

III.3.3. Windows style

Windows style preference enable to change color, font and size of windows. In this preference only workpiece, information bar and output messages can be changed.

Fig.III.6 Windows Styles tab

Fig.III.7 Changing color

Page 15: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 12

S H A P E

III.3.4. Hardware summary

Hardware summary preference gives graphic information. There is nothing to change values, just giving information.

Fig.III.8 Hardware Summary tab

Note) In this preference menu, default values are recommended. Note) You can designate your working files to appropriate folders by selecting them in the Directories folder of Preference window.

Page 16: RR Manual All

olutions for ighly dvanced rocess ngineering

III. Overview of SHAPE-RR 13

S H A P E

III.4. Using The Mouse to Control Object The mouse buttons have a consistent use in SHAPE-RF pre- and post-processors to control the objects in the main display window. The Alt + Right button is used for rotating an object; Left and Right mouse button is for translating the object. The usage of mouse button Keys and hot key are explained at Table 1. The some hot keys are available only when Auto Focusing is not active.

Table 1 Use of "hot keys" and mouse button

Key Mouse Button Action

Alt Right Rotation about an arbitrary axle in space

Ctrl Right Rotation about Z-axle

Ctrl Left Panning in arbitrary direction (if Auto-focusing turned off)

Left+Right Panning in arbitrary direction (if Auto-focusing turned off)

Shift Right Zoom in or out(if Auto-focusing turned off)

Wheel Up scroll: zoom in Down scroll: zoom out

Alt+1 Displaying the object in isometric plane

Alt+2 Displaying the object in X-Y plane

Alt+3 Displaying the object in Z-Y plane

Alt+4 Displaying the object in X-Z plane

Ctrl+1 Change the canvas plane to X-Y, Y-Z, Z-X plane by turns

Ctrl+2 Change the canvas plane to X-Y plane

Ctrl+3 Change the canvas plane to Y-Z plane

Ctrl+4 Change the canvas plane to Z-X plane

Page 17: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 14

S H A P E

IV. Pre-processing Pre-processing is for preparing the data set so that the solver has all the needed information to simulate a ring rolling process. SHAPE-RR is a three dimensional FEM package highly oriented user and process. Windows used in SHAPE-RR is almost closed to Microsoft programs which users are used. Therefore, SHAPE-RR pre-processing consists of step-by-step procedure. Because it is only for ring rolling process, there is no extra process condition setup. The usual finite element simulation needs complicated “mesh”, which models the workpiece numerically. Also, it needs material properties and process parameters. But in the SHAPE-RR pre-process, auto mesh generation is offered. Also user define is possible. So, preparing the input data is so simple and easy that even a beginner can be a master of the SHAPE-RR pre-processing in a moment.

IV.1. Getting Started

IV.1.1. New Project

To start up SHAPE-RR, double click the icon of SHAPE-RR, .

Fig.IV.1.1 New menu

Sure, there is nothing because any file is not opened. Click icon (or File>New), to open empty project. Select the process type and click OK

Fig.IV.1.2 Selection of Project Type

Page 18: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 15

S H A P E

Fig.IV.1.3 New project

IV.1.2. File Opening The files which is available to SHAPE-RR are RRI, RSF files. The file having extension RRI is the input file for simulation. The file having extension RSF has the results of steps. To open an existing SHAPE-RR file, you can select Open from the File menu. You can also open files by dragging them from Windows Explorer into SHAPE-RR. If you drop one or more drawings anywhere outside the drawing area, for example, the blank space next to the toolbars, SHAPE-RR opens the drawings. You can double-click a drawing in Windows Explorer to launch SHAPE-RR and open files.

Page 19: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 16

S H A P E

IV.1.3. RRI Opening The RRI file has the information of geometry and the various conditions for solving. It can be generated by Export from File menu. Although the project is started empty by New menu, the RRI file is generated automatically by SHAPE-RR before solving.

Fig.IV.1.4 RRI open

Fig.IV.1.5 Export RRI

IV.1.3.1. RSF Opening The RSF file has a lot of results of steps. If you open the RSF file, the Out-put file open dialog box will be shown as Fig.IV.1.6. You can see the list of included steps. Then you can select files you want to open. While SHAPE-RR is solving, you can also select the mesh-system to be opened.

Fig.IV.1.6 Opening out-put files

Page 20: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 17

S H A P E Click OK, then the files selected will be opened shown as Fig. IV.1.7. Warning) If too many steps opened, the software will be put pressure upon, and even may be done not response.

Fig.IV.1.7 RSF open

Note) The results file extension of SHAPE-RR changes to RSF. But RRS, UNV file which is previous that of SHAPE-RR is still available.

Fig.IV.1.8 Changing mesh system Fig.IV.1.9 Import Result Step

If you want to append other steps to current project, use the Import from the File menu. For examples, If you want to append results of two steps, select same RSF file with same mesh-system.

Fig.IV.1.10 Selection of steps

Then the results of two steps will be appended to current project as shown Fig.IV.1.11.

Page 21: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 18

S H A P E

new imported steps

Fig.IV.1.11 Appended steps

IV.1.4. Coordinate System SHAPE-RR has two sub-work modes, Primary Layer and Drafting Layer in Design mode. In Drafting layer mode, drawing process is executed. For example, importing roll and ring, register ring and roll. Other almost processes are executed in Primary layer mode. SHAPE-RR basically gives XYZ coordinate, as followings.

IV.1.4.1. Primary Layer The default coordinate system of Primary Layer is yz plane as follow figure.

Z

Y

X

Fig.IV.1.12 Coordinate system in Primary Layer

Page 22: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 19

S H A P E

IV.1.4.2. Drafting Layer The default coordinate system of Dafting Layer is xy plane as follow figure.

Z

YX

Fig.IV.1.13 Coordinate system in Drafting Layer

Page 23: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 20

S H A P E

IV.2. Import Geometry CAD data only can be imported by DXF/IGES format as mentioned before.

IV.2.1. Draw ring and rolls in the CAD software If the project is first stage, drawn CAD files could be needed. But three things should be considered in the CAD software to export. First, CAD files must be saved as DXF/IGES file format. DXF file means Data exchange Format, and IGES file means Initial Graphics Exchange Specification. They are a standard format describing data. Second, CAD data of ring and rolls should be drawn on the XY plane, even though both ring and rolls are seen YZ plane in the SHAPE-RR. Third, base point of ring and main roll had better be matched. But there is no fixed base point, it is up to user’s preference. In this example, base point of ring and main roll are shown next page. Note) AutoCAD R12/LT2 DXF version may occur errors when imported. Note) The IGES file can be imported without distinction of IGES version. But currently the dataset number is restricted. The available dataset number is only 106, 110, 126.

IV.2.2. Base point Base point of ring and rolls had better be matched for reducing the step of pre-process in SHAPE-RR. When there is no fixed base point, it is up to user’s preference. But it is important that it is concerned with rotating center (rotating center is mentioned in the Radial section properties later) which determines ring’s outer diameter.

Fig.IV.2.1 Base point

Ring and main roll’s base points are combined in the SHAPE-RR as following figure. These two points had better be matched to each other. Generally it is proposed that the base point be same as the origin point of coordinate system, (0.000,0.000,0.000).

Page 24: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 21

S H A P E

Base

Fig.IV.2.2 Base point in SHAPE-RR

Page 25: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 22

S H A P E

IV.2.3. Draw ring in the CAD software CAD data of right side ring profile should be drawn. You do not need to draw whole ring, just draw right section of the ring. SHAPE-RR automatically converts two-dimensional section into three-dimensional ring. On the coordinate system of SHAPE-RR, the section to be drawn is on Y-Z plane. But you should note that the section must be drawn on X-Y plane with CAD software as shown Fig.IV.2.3. Fig.IV.2.4 shows the drawing describing a ring in AutoCAD.

Fig.IV.2.3 Right section of ring

Fig.IV.2.4 Drawing ring profile

The ring geometry must have a continuous ring profile and a center mark. But if the base point is same as base point on CAD, the center mark does not need any more. It is important that the scale of dimension must be same. That is 1:1. The dimension of the drawing retains to SHAPE-RR.

IV.2.4. Draw rolls in the CAD software

As drawing of ring profile, CAD data of right side roll profile should be drawn. The roll must be described to Y-Z plane profile taken half geometry in SHAPE-RR because on the coordinate system of SHAPE-RR, the section to be drawn is on Y-Z plane. But you should note that the section must be drawn on X-Y plane with CAD software as shown Fig.IV.2.5.

Page 26: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 23

S H A P E

Fig.IV.2.5 Section of roll on Y-Z plain in SHAPE-RR

Fig.IV.2.6 Roll profile

The roll geometry must have continuous roll profile(s), axle profile(s). The line entity describing axle must be longer than each ends of roll profile shown as Fig.IV.2.6. If the geometry is laid on the coordinate of the base point, the center mark does not need any more. In the same case as ring, the scale of dimension must be same. The dimension of the drawing retains to SHAPE-RR. Although a drawing has many roll geometry, only one roll data can be imported at once. You should note that currently the roll drawn within one axle can be only imported. Fig.IV.2.7. shows a drawing describing two rolls in AutoCAD.

Fig.IV.2.7 Drawing roll profile

IV.2.5. Import geometry files To import CAD data, SHAPE-RR is in Drafting Layer mode. After changing layer mode to Drafting Layer, select Design >> Import Geometry. And find CAD files in the directories.

Page 27: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 24

S H A P E

Fig.IV.2.8 Import Geometry

Fig.IV.2.9 Import DXF file

Fig.IV.2.10 Import IGES file

IV.2.6. Import Roll To import roll set data, click Roll geometry.

Page 28: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 25

S H A P E

Fig.IV.2.11 Roll geometry type

The Margin error of geometric calculation is to define geometric error. It must be considered to import successfully. If the scale of dimension of the drawing is large, it needs large margin error vice versa. If you want to change margin error, click Setting button.

IV.2.6.1. Margin of Error

Fig.IV.2.12 Margin of error

• Radius of circle to be regarded as a same point: If the edge point of any entity is in the circle having this radius at the edge point of neighbor entity, then the two entities are regarded as being attached each one of two edge points of an entity. • Tolerance of length: A margin error for comparison of length.

Page 29: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing

S H A P E• Tolerance of angle: A margin error for comparison of angle.

IV.2.6.2. Others

• Significant decimal point to be preserved: It is to prevent against a propagation of error while CAD calculation as a preservation data down to this significant decimal point.

• Significant decimal point to be truncated: It is to ignore data up to this significant decimal point while distinction of data between nontrivial and trivial.

After clicking OK, Import Geometry window appears.

IV.2.6.3. Import Information of Geometry You can define or change the properties of object to be imported.

Fig.IV.2.13 Import information

Note) The screen of Import Geometry can be controlled with manipulating mouse controller like below table.

Mouse Controller Function Left & Right Button Translation

Scroller Scaling

• Object list It shows rolls to be imported. Also you can verify the properties of roll. • Profile table SHAPE-RR uses the simplified method which describes geometric profile of section of roll or ring. It is available when all points are on same plane. In Fig.IV.2.14, the curve is consisted of three lines and two arcs on X-Y plane. The curve can be described as P1 - P3 - P6 - P8. In where, P3 and P6 are include the radius value of arc in Z coordinate.

26

P3

y

x

P8

P7

P4

P5

P6

R2

R1

P2

P1

Page 30: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 27

S H A P E

Fig.IV.2.14 Description of profile

The profile table is just to show geometrical roll data. It is impossible modify roll data in this window. Hide useless points option is to show or hide the bound points between line and arc entity. For example, in Fig.IV.2.14, if it is checked the curve can be described as P1 - P3 - P6 - P8. If it is unchecked the curve can be described as P1 - P2 - P3 - P4 - P5 - P6 - P7 - P8. Relative coordinates option makes transform the coordinates of profile to the local coordinates which the origin point is a start point of axle and the X axis is the line that is from start to end point of axle.

Fig.IV.2.15 Local Coordinates

Fig.IV.2.16 Global Coordinates

Page 31: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 28

Show t it is unchecked, the information, the coordinate of a mouse cursor and the number of each entity, will

be hidden.

S H A P E

• able If

Fig.IV.2.17 Hiding table

modified by Roll Profile definition. The geometry modification function is operated in rafting layer.

n workpiece bar which is needed to modify on ‘Primary Layer’ mode. Then ‘Axle-**’ is

Click the right button of mouse, and menu window appears as Fig.IV.2.18.

IV.2.6.4. Modification of roll geometry

The roll geometry can beD The sequence of modification is as follow. ; Select the ‘Axle-**’ iactivated, in blue line.

Fig.IV.2.18 Modify “Axle-**” Profile menu

Selecting the modification menu, ‘Modify “Axle-**” Profile’, the layer mode is changed from Primary layer to

Click the “Design>>Roll Profile Definition” for modification of roll profile. Drafting layer.

Page 32: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 29

S H A P E

Fig.IV.2.19 Roll Profile Definition menu

Modify the values of x, y, Radius as following Fig.IV.2.20.

Fig.IV.2.20 The modification of roll geometry

Page 33: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 30

S H A P E

IV.2.6.5. Register Roll This process is to transfer coordinate system from xy plane(coordinate system of initial importing geometry) to yz plane.

Fig.IV.2.21 X-Y plane Fig.IV.2.22 Y-Z plane

Fig.IV.2.23 Register Axle of Roll

• Axle start The coordinate of the start point of a new axle (P2 in Fig.IV.2.22) is automatically imported as that of original CAD drawing. For example, if P1 is (x1, y1, 0) in original CAD drawing, then P2 is (0, x1, y1). If you want to remember coordinates of start and end points of an importing roll axle, refer the following sentence. You can know those in importing process. Point the end point of axle with mouse in import geometry window, then its coordinate is shown in a left upper window as bellow figure.

Fig.IV.2.24 Coordinate of Axle

• Direction Vector

After appointing of axle start point, the direction vector should be appointed. Direction vector shows a direction of axle. So its magnitude is indifferent.

P1

P2

Coordinate of Axle

P1

Page 34: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 31

S H A P EIf start point of axle and its direction vector is appointed, the end point of axle is fixed.

Press OK, then roll appears in main window as Fig.IV.2.25

Fig.IV.2.25 Roll feature after Roll Register

IV.2.7. Import Ring To import ring profile data that already made in CAD program, select Section profile geometry. Other things are same as Roll geometry.

Fig.IV.2.26 Section profile geometry type

Press ‘OK’, when above options are completed. Then you can see as below, Fig.IV.2.27.

Page 35: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 32

S H A P E

Fig.IV.2.27 Type of symmetry

IV.2.7.1. Register Preform After ring geometry is imported, register that.

Fig.IV.2.28 Register Preform Menu

Click the Design>>Register Preform, then follow window appears.

Fig.IV.2.29 Register Preform window

• Type of symmetry : Type of symmetry is for selecting what ring is XY plane symmetric or asymmetric. This option is important for setting boundary condition later.

• Rotation axle :

Page 36: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 33

S H A P ERotation axle is driving axle of ring. Type the proper values. • Move perform profile along with axle : Unchecked : If you change the values of rotation axle, then ring size is changed. Checked : Although you change the values of rotation axle, ring size is not changed but is translated as axle translated. Fig.IV.2.30 shows a feature which is imported two rolls and a ring.

Fig.IV.2.30 Imported feature

Note) If the ring pre-form is not seen, check ring pre-form icon activated or not. Also if the rolls are not seen, check roll icon activated or not.

Fig.IV.2.31 Show and hide icon of the rolls

Fig.IV.2.32 Show and hide icon of the preform

Note) If the pre-form of ring and rolls are seen many-sided, check customised style in the Feature pull down menu. The number of subdivisions along the Z axis has values between 12 and 180.

Fig.IV.2.33 Imported feature

Page 37: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 34

S H A P E

Page 38: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 35

S H A P E

Fig.IV.2.34 The number of subdivisions along the Z axis: 50

Fig.IV.2.35 The number of subdivisions along the Z axis: 12

Page 39: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 36

S H A P E

IV.3. Preparation For A Running Solver

IV.3.1. Initial section profile SHAPE-RR supports a mesh generation of section profile of preform automatically. To use this function, you must do sampling for section layout and assign density for sampled points. Also you can import section mesh from *.UNV which is created by IDEAS.

IV.3.1.1. Using auto mesh generation Click the menu of Initial section profile in the pull down menu of Pre-process, then Sampling of the section lay-out window appears. Default value is shown as bellows. Because mesh of default value is coarse, mesh is divided more fine.

Fig.IV.3.1 Initial Section Profile menu

Fig.IV.3.2 Sampling points of lay-out

Note) The screen of Import Geometry can be controlled with manipulating mouse controller like below table.

Mouse Controller Function Left & Right Button Translation

Scroller Scaling

• Dividing Entity

Select the Sampling and No operation, if you want divide node evenly. Point line where user want to divide node, and line is activated. Then click twice to divide.

Page 40: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 37

S H A P E

Fig.IV.3.3 Dividing entity

• Create & Erase describing points To create node manually on the line, select Create radio button and point where want to make node.

Fig.IV.3.4 Creation of sampling point

To erase node on the line, select Erase radio button and point where want to remove node.

Page 41: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 38

S H A P E • Rotating center

Fig.IV.3.5

Rotating center

Rotating center means ring’s rotating center. But it is not always mean ring’s diameter. Ring’s diameter also depends on where user sets ring’s zero point.

• Sampling Condition

Fig.IV.3.6 Sampling condition

Sampling condition show two kinds of option. First, Total number of points shows how many nodes are selected. Second, Minimum Length of # is minimum length of element. Click OK to finish initial section profile.

IV.3.1.2. Importing section mesh You can import the section mesh from UNV file which is created by IDEAS. It can be realized through Import Geometry menu.

Fig.IV.3.7 Import geometry menu

Page 42: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 39

S H A P E

IV.3.2. Boundary condition Boundary condition is for limiting movement of nodes. This is only under Symmetric condition of ring section. If ring section of XY plane is asymmetric, skip boundary condition.

Fig.IV.3.8 Boundary Condition menu

In the SHAPE-RR, user only changes boundary condition as Not translate to Z direction in case of ring profile is XY plane symmetric because others are physically useless. Default condition is Free. If user wants to change Not translate to Z direction, select nodes with dragging mouse which on the neutral axis.

Fig.IV.3.9 Definition of boundary condition

Note) Unless nodes are selected, click Filter icon in the Tool full down menu. That is not because there is no nodes or bug, but because no object type can be selectable.

Fig.IV.3.10 Filter menu

Set selection Filter appears.

Page 43: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 40

S H A P E

Fig.IV.3.11 Setting selection filter

Select an object that you want to select in Object List and click icon. Selected object moves

from Object List to Selectable. If you want to select all objects in Object List, click icon. (No need to

select any object in Object List). The selection of object(s) can be deselected by clicking the icon or

icon.

Page 44: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 41

S H A P E

IV.3.3. Radial Section Properties Radial section property is the most important in the pre-process and easy to make mistake. In this reason user must be aware of Radial section property menu perfectly. Radial section property is for making elements to simulate finite element method.

Fig.IV.3.12 Radial Section Properties menu

After clicking Radial Section Property menu, users meet as following figure. In the Radial sections box, users can define number of AMS and SMS. Note) About AMS and SMS, mentioned in the chapter II.2 Mesh system.

Fig.IV.3.13 Properties of radial sections

Page 45: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 42

S H A P E* Properties of Radial Sections - Default value of Number of radial section of AMS is 180 - Default value of Number of radial section of SMS is 30. - Number of angular symmetry :

It means number of symmetric deformation area in workpiece.

1

Number of angular symmetry : 1 Start angle of radial section : 90o

- Start angle ( ) of radial section of SMS : Default value 0o θFor convenience of seeing the cross section of deformation area, you had better set this value to 90o.

3

2

1

Number of angular symmetry : 3 Start angle of radial section : 0o

Page 46: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 43

S H A P E

0o

θ

-Value of Y axis of initial rotation center of perform is same as Rotation center of workpiece in the Initial section profile menu.

Fig.IV.3.14 Rotation center

IV.3.3.1. Number of Radial Section of AMS

Fig.IV.3.15 Actual mesh system

Number of radial section of AMS means how many elements in the 360 degrees. If user type “180”, it could mean that elements are made every 2 degrees evenly.

Page 47: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 44

S H A P E

IV.3.3.2. Number of radial section of SMS

Fig.IV.3.16 Spatial mesh system

Default value of Property of SMS is Manually generate the radial section mesh. This option divides meshes manually that’s in cases. Currently, Automatically generate the radial section mesh option is not supported.

Fig.IV.3.17 Property of SMS

Number of radial section of SMS also means how many elements in the 360 degrees. But SMS mesh system is not evenly divided by degree. SMS has coarse mesh in the rigid zone, by contrast fine mesh in the deforming zone. In this reason, meshes are divided manually in the SMS. In this user’s manual from 90 degree to 120, it assumed as deforming zone. So user divides mesh finely in this zone. At first there is nothing in the Boundary condition of radial section of SMS, so proper number should be typed. After selecting angle 90 and 120, click left mouse button. Then simple box which Boundary condition, Insert, Divide, Delete is shown is appeared. In there, select Divide to divide meshes finely.

Page 48: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 45

S H A P ENow, divided angles are shown as following figure. [Preprocess -> Radial section property] Select the region to divide, this region will be deformation region.

Click the Divide button, and number of dividing value (in here 10)

The region of 90o~120o is divided by 10 pieces.

Fig.IV.3.18 Dividing angle of SMS

Note) Number of radial section of SMS is not assumed under specific information. So Number of radial section of SMS has variable value that’s in pressure roll size compare to ring. But usually between 90° and 120° are guessed as deforming zone.

Page 49: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 46

S H A P E

IV.3.3.3. Change Boundary Condition Already boundary condition is mentioned about symmetric problem, and in the Radial section properties boundary condition is totally same concept. It is for limiting movement of nodes. Boundary condition menu is only for symmetric condition. Contrastively Boundary condition of radial sections of SMS is not concerned with symmetric. So this procedure is essential, not optional. As being mentioned before, Number of radial section of AMS is not concerned with calculating time. Calculating time is only depends on how many number of radial section of SMS. Sure, fine mesh gives more accurate result, takes more time. [Preprocess -> Radial section property] After dividing the radial section, you should set up the boundary condition of each sections which are predicted to be deformable area. Select the divided region in table, and click the condition button

Fig.IV.3.19 Boundary condition menu for SMS

Page 50: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 47

S H A P ECheck the Belongs to deforming region, number, in Contact selection window and insert number 1…. If roll is clamping roll, this value becomes 0(zero), or not integer which is bigger than zero. (refer to IV.3.5 Roll Property)

Fig.IV.3.20 Contact conditions

Boundary condition of deforming region has changed.

Fig.IV.3.22 Radial section properties

Click OK, then you can verify the pre-estimated SMS if the radial section mesh is generated manually and Pre-estimated SMS icon is active.

Fig.IV.3.23 Pre-estimated SMS icon

Page 51: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 48

S H A P E

Fig.IV.3.24 Pre-estimated SMS

Page 52: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 49

S H A P E

IV.3.4. Material properties You can define the material properties as form of flow stress equation. Currently the SHAPE-RR contains only one flow stress model, exponential hardening model.

IV.3.4.1. Flow stress equation

Fig.IV.3.25 Material properties: Flow Stress Equations

The flow stress of a material is a function of strain and stain rate in cold forming. Therefore, the flow stress (σ) of a material is assumed to have the following relation,

22 )()( 10100ba bbaa εεσ &++= K

If you have some experimental data such as UTS (Ultimate tensile stress), Yield strength(Y0), SHAPE-RR can convert the known parameter to the flow stress.

Fig.IV.3.26 Stress-Strain Curve for Table 2

Table 2 used properties in Fig.III.10.

Page 53: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 50

S H A P E

Steel Aluminum

Y0 800 Y0 340

a2 0.2 a2 0.13

a1, b0 1 a1, b0 1

a0, b1, b2 0 a0, b1, b2 0 <Example> A strain-rate sensitive material with the flow stress

Y0 A0 a1 a2 b0 b1 b2

8.15 1.0 0.0 0.0 0.0 1.0 0.094 Perfectly plastic material should be like this

Y0 A0 a1 a2 b0 b1 b2

1.0 1.0 0.0 0.0 1.0 0.0 0.0

IV.3.4.2. Mechanical Properties

Fig.IV.3.27 Material properties: Mechanical Properties

• Physical properties Young’s modulus (Mpa) Poisson’s ratio Maximum plastic strain Yield Strength(Mpa) Ultimate tensile strength(Mpa)

Page 54: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 51

S H A P E• Heat properties Thermal conductivity (N/sec-K) Heat capacity (N/mm2-K): (mass density x specific heat) Friction of plastic work converted to heat

IV.3.4.3. Material Database SHAPE-RR allows you to make your own material database as following figure.

Fig.IV.3.28 Material properties: Material Database

• Material: name of material

• Flow stress equation

Type : Type 2 is the equation, 22 b

10a

100 )bb()aa( εεσ &++= K . K[Mpa] : Strength coefficient: a0 : Initial strain a1 : Strain constant n : Work hardening exponent b0 : Initial strain b1 : Strain rate constant m : Strain rate sensitivity

Page 55: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 52

S H A P EAs in IV.3.4.1 Flow stress equation, if you have some experimental data such as UTS (Ultimate tensile stress),

Yield strength(Y0), the known parameters to the flow stress can be converted.

Fig.IV.3.29 Convert to flow-stress parameter

• Mechanical Properties Mechanical properties of material can be set as in IV.3.4.2

Fig.IV.3.30 Material properties: Material Database_Seetings

• Delete Delete the material item from material database.

• Save Save the new or changed material properties in database.

• Load Load the material properties as the material condition of this simulation.

Page 56: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 53

S H A P E

IV.3.5. Roll properties In Roll Properties, the velocity condition and the physical properties of roll can be defined.

Fig.IV.3.31 Roll properties menu

Fig.IV.3.32 Roll properties

• General Roll ID : number of roll.

If you want to solve the ring rolling process with SHAPE-RR, you should take care of the sequence of roll id number. But if you want to solve the spinning process, you don’t need to be careful about numbering of the roll id.

Table 3. Sequence of roll id number in ring rolling simulation

Roll Type Number Main Roll 1 Pressure Roll 2 Side Roll 3 Side Roll 4

Click the Set button for changing roll ID. Then following window appears. Type the Roll ID and press OK.

Page 57: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 54

hange Roll ID

Rolls that are set in same deformation part of ring have the same deformation region ID.

S H A P EFig.IV.3.33 C

Deformation region ID : number of deformation region.

Fig.IV.3.34 Cha formation nge De Region ID

Value Roll property

0 Clamping roll Deformation region id

1,2,3… Driving roll, Idle roll

Page 58: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 55

S H A P E• Movement control in Roll Property

1. Time, Stroke, or workpiece outer diameter VS Velocity Generally the pressure(mandrel) roll moves to Y direction. The roll velocity can change according to (see Fig.IV.3.35 a)) following units ;

1. Time 2. Stroke 3. Designated workpiece outer diameter

Then you can define changing movement condition as well as constant value(see Fig.IV.3.35 a)). The value of roll movement is generally velocity.

Fig.IV.3.35 a) Roll movement control – various movement You can change the movement values by click the add/delete/modify button. (see Fig.IV.3.35 b) )

Fig.IV.3.35 b) Movement condition with Velocity 2. Time,Stroke, or workpiece outer diameter VS Force when the rollis the clamping roll (Deformation region ID is 0) on Z direction, the force is also available. (see Fig.IV.3.36 a) )

Page 59: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 56

S H A P E

Fig.IV.3.36 a) Roll movement control(2)

You can change the clamping force by click the add/delete/modify button. (see Fig.IV.3.36 b))

Fig.IV.3.36 b) Movement condition with Clamping Force

Page 60: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 57

S H A P E• Adjust roll to workpiece before starting analysis: This function is to move the roll to workpiece when roll and workpiece have no contact area. You had better check this function to save the calculating time.(see Fig.IV.3.36 c) )

Fig.IV.3.36 c) Adjustcent option bet. workpiece and roll

* Check: When roll is adjacent to workpiece, analysis is started. * Uncheck: No matter roll is adjacent to workpiece or not, analysis is started. • Physical Properties * Friction Factor(m) of roller : Friction between roll and workpiece. (0<m<1)

Frictin factor can be defined rate between shear strength( iτ )of contact area and shear yield stress( ). If m is zero, there is no friction. If m is 1.0, it is sticking condition.

k

km iτ=

* Roll temperature(Celsius) : Initial roll temperature (when thermal analysis)

Page 61: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 58

S H A P E

IV.3.6. Simulation environments Simulation environments is to define the simulation conditions and roll properties and material properties.

Fig.IV.3.37 Simulation environments menu

IV.3.6.1. Process conditions

Process Condition is for determining simulation environment and process condition. Also, unit is determined in the process condition.

Fig.IV.3.38 Process conditions

• Step Condition:

i) Stroke increment

Fig.IV.3.39 Process conditions according to Stroke increment

Page 62: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 59

S H A P E

Allowable stroke per step : Define the stroke value roughly per step. This value may be different value from simulation

Total stroke Total stroke of driving roll

Step frequency saving result Step interval of simulation

Initial stroke You’d better set this value 1/1000 of allowable stroke

Allowable tolerance fator between node and roll(die)

Page 63: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 60

S H A P E

ii) Time increment

Fig.IV.3.40 Process conditions according to Time increment

Allowable stroke per step : Define the stroke value roughly per step. This value may be different value from simulation

Total time : Total time of process

Step frequency saving result :Step interval of simulation

Initial stroke : You’d better set this value 1/1000 of allowable stroke

Allowable tolerance fator between node and roll(die) :

Page 64: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 61

S H A P E

IV.3.6.2. Remesh option Remesh option is to use auto-remeshing during the simulation. The remeshing will be executed if following conditions go over even one criterion.

Fig.IV.3.41 Remesh option

At first, check the “Use Remeshing” button • Maximum step increments:

Each step increments the remeshing will be executed. • Minimum elemental angle:

If any acute angle falls under minimum elemental angle for two dimensional mesh of all radial section, the remeshing will be executed.

θ

Fig.IV.3.42 Mininum elemental angle

IV.3.6.3. Numerical analysis conditions This numerical analysis options are only for advanced user who are used SHAPE-RR. So, It is proposed to use default value.

Page 65: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 62

S H A P E

Fig.IV.3.43 Numerical analysis condition

Tolerance error limit for fractional norm (RTOL)

During the Newton-Raphson iteration process, it is assumed that the solution has converged if the fractinal norm is less than RTOL. RTOL=10-4-10-5 is desirable.

Tolerance error limit for functional norm (FLIMIT)

During the Newton-Raphson iteration process, it is assumed that the solution has converged if the fuctional norm is less than FLIMIT. FLIMIT=10-2-10-3 times of initial yield stress is desirable. If the solution error is within both ROTL and FLIMIT, then the solution is regarded as completely converged one.

Penalty constant to enforce volume constancy (DIAT)

Penalty constant DIAT should be a larger positive number. DIAT=105-106 is desirable.

Starting value of deceleration to improve the convergency of solution (ACOEF)

Starting value of deceleration to improve the convergency of solution by the Newton-Raphson iterative method. When the solution is well behaving, deceleration coefficient is set to 1(unity), But it is frequently necessary to start the deceleration coefficient with small value. e.g., 0.1-0.2 (For more detail about iterative methods and deceleration coefficient)

Limiting value of effective strain rate (ALPH)

Limiting value of effective strain rate within which the material is considered to be rigid. ALPH=0.001 is desirable for the normal range of ring rolling processes

Approximate average strain rate (VPCT)

VPCT is used only when the initial guess is generated for the first time by direct iterative method. VPCT=0.01-0.1 is desirable for the normal range of ring rolling processes.

Page 66: RR Manual All

olutions for ighly dvanced rocess ngineering

IV. Pre-processing 63

S H A P E

IV.3.7. Project location Project location is for saving output files of simulation.

Fig.IV.3.44 Project Location menu

Type the project name and folder name which you want. Then automatically folder is made in the given directory.

Fig.IV.3.43 Setting project location

Note) There is no use to make directory to save output files. After naming Project folder, named folder is automatically made.

Page 67: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 63

V. Solution Phase V.1. Starting the simulation To start the finite element simulation, it is necessary to ready to solve. The solver reads “xx.rri” file that is created SHAPE-RR after proper pre-processing or started with RRI file. All the data in “xx.rri” are legal, then the solver is ready to start.

Fig.V.1.1. Solution menu

Note) If Start/Resume is not highlighted or not ready for activation yet, you can't use it. To use this command, please follow up the proper procedures described in the previous chapters.

Fig.V.1.2. Ready to solve

To start up the solver, push Start/Resume from Solution menu. If the input data is valid, you can see the message from Output bar as shown below figure.

Page 68: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 64

Fig.V.1.3. Output message

You can monitor the simulation status by activating the output bar. During and after the simulation, you can investigate the simulation results by using the post-processor of SHAPE-RR. When the solver is starting to run, the Windows OS becomes very busy to assign memories and to allocate temporary files into somewhere in your hard disk drive. This work lasts for a minute. Therefore, you will feel suddenly that SHAPE-RR is very slow and some functions do not work well. But, this is normal. The Windows OS is too busy to handle with SHAPE-RR. If you avoid this occupation of system resource, change Task Priority. It is to control the order of priority to resource. Highest means that the SHAPE-RR is the most prior than others in the processor of system. So you can control the order of priority to use the system harmoniously with other applications.

Fig.V.1.4. Task priority

Page 69: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 65

V.2. Controlling the solver While solving the project, you can stop simulation and pause simulation momentarily from Solution tool bar. Also you can change the order of task-priority.

Fig.V.2.1. Solution tool bar

Solver management icons offer this function.

Table.1. Solver management icons

Tool bar Command Description

Start Start SHAPE-RR Solver

Pause Pause SHAPE-RR Solver

Stop Stop SHAPE-RR Solver

Tasks Priority Control the speed of SHAPE-RR Solver

Page 70: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 66

V.3. Restarting from the existing file From time to time, it is necessary to restart the current design from a specific step with a slightly different (modified) design, not from the beginning. Is it possible? Yes, if you only have the necessary files up to the specific step, which means you already simulated the design once in a while and you know the location of the files.

Open RSF file from Project location folder.

Fig.V.3.1.(a) Open RSF format file.

Click Restarting Strategy button to restart.

Fig.V.3.1.(b) Pre-Process menu

If simulation step is finished until 3 step, user can start the simulation between 2 step and 4 step. In this window users can change directory where user want to save. Select step where user want to start. Then click OK to restart.

Fig.V.3.2. Restarting Option menu

Page 71: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 67

V.4. Restart with modified environments You can restart with modified environments. The below items can be modifiable. • Roll geometry • Movement condition of roll • Section mesh • Radial section properties • Simulation environments

V.4.1. Preparation The procedure for setting up restarting is same as the case of previous chapter.

Fig.V.4.1 Restart Strategy dialog box

If the setting of restarting is completed, then you can change each items.

Page 72: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 68

V.4.2. Change of roll If you want to change the roll, you must erase the exist roll to be changed, and import the new roll.

Fig.V.4.2. Deleting a axle

Fig.V.4.3. Import menu

The below figure shows that the new main(forming) roll is being imported to SHAPE-RR.

Fig.V.4.4. Importing Geometry dialog box

Fig.V.4.5. New roll

Page 73: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 69

Where, if the new roll is imported, you must define the roll properties.

Fig.V.4.6. Roll properties

V.4.3. Change of section mesh SHAPE-RR supports re-meshing as the simulation restarts. The sectional outline of the SMS solution will be initial section profile. With this profile, you can make re-meshing by means of two methods.

V.4.3.1. Using the auto mesh generation The procedure of using the auto mesh generator is same as mentioned chapter III. You do sampling the outline of section profile in Initial section profile from Preprocess menu.

Fig.V.4.7. Sampling for outline

Next, assign the density to sampling.

Fig.V.4.8. Sampling condition

Page 74: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 70

As the mesh is made different by the number of minimum length, you should try the meshing until getting good meshed section.

Fig.V.4.9. Meshed section

V.4.3.2. Using the mesh data

You can import the mesh data as the mesh of initial section. But only UNV(Universal, not it of SHAPE-RR) file is available. It is noted that the section profile used in outer mesh generator must be same as the sectional outline of workpiece. When you make a drawing in outer mesh generator you should work on X-Y plane. Although the initial section of SHAPE-RR is on Y-Z plane, you need not to consider its transformation. The SHAPE-RR will transform X-Y plane to Y-Z plane.

Fig.V.4.10. Sectional shape of workpiece

The SHAPE-RR supports the exporting geometry. You can export the geometry to DXF file and IGES file. As using this function, you can export the sectional shape of workpiece correctly. For example, if you want to generator a mesh as using IDEAS, you have to export the sectional outline of workpiece to IGES formatted file.

Fig.V.4.11. Preprocess menu

Page 75: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 71

Fig.V.4.12. Exporting geometry

To import the exported IGES file in the IDEAS, you must start with Design application.

Application Design

Task Master Modeler

Fig.V.4.13. Importing to IDEAS

The below figure shows the IDEAS imported the section profile successfully.

Fig.V.4.14. Imported section to IDEAS

Then you do mesh the imported section with the IDEAS

Fig.V.4.15. Meshed section in IDEAS

Page 76: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 72

After the meshing, you can export the mesh data to UNV(Universal) file.

Fig.V.4.16. Exporting mesh data

Then you have to try import the UNV file to the SHAPE-RR.

Fig.V.4.17. Importing mesh data

It can be accomplished as Import Geometry command from Preprocess menu.

Fig.V.4.18. Selecting file

If the importing is executed successfully, you can see the meshed section as a below figure.

Fig.V.4.19. Imported mesh data

V.4.4. Change of radial section property You can change the radial section properties as restarting. The method of setting for radial section properties is same as mentioned chapter V.3.

Page 77: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 73

Fig.V.4.20. Radial section properties

After changing the radial section properties, you can verify the spatial meshed solid as you set the properties of SMS.

Fig.V.4.21. Pre-estimated SMS

V.4.5. Change of simulation environment Also you can change the process conditions and the numeric analysis options in the Simulation environments.

Fig.V.4.22. Simulation environments

Page 78: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

V. Solutions 74

After that, you can restart with modified environments.

Fig.V.4.23. Solve menu

Page 79: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 75

VI. Post processing phase

This Chapter is for ‘Post processing phase’ to examine the results of analysis. Results of analysis can be shown such as, distribution of ‘Effective strain’, ‘Strain rate’ and ‘Longitudinal strain’ etc… and by using the GUI of SHAPE-RR the curve of the results can be created variably.

VI.1. Files for post-processing You can open project-name.RSF file for the post-processing. The file with extension RSF, may include a lot of results of steps. The UNV or RRS, TAPE file is not generated by the solver any more. But the new version still accepts those files.

VI.1.1. RSF File The RSF file has a lot of results for number of steps. If you open the RSF file, the Out-put file open dialog box will be shown as Fig.VI.1.5. You can see the list of steps that is included in RSF file. Then you can select files you want to open. You can also select the mesh-system to be opened.

Fig.VI.1.1 Opening out-put files

VI.1.2. Importing RSF File After opening RSF file, if you want to append other steps to current project, use the Import from the File menu.

Fig.VI.1.2 Import RRS

For examples, If you want to append results of two steps, select same RSF file. And select two steps with same mesh system.

Page 80: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 76

Fig.VI.1.3 Select steps

Then the results of two steps will be appended to current project as shown Fig.VI.1.4.

Fig.VI.1.4 Appended RRS files

VI.2. Issues of The Analysis While SHAPE-RR is solving, SHAPE-RR produces two solution files which is result by each mesh-systems, respectively AMS, SMS. Each mesh-systems show different result like below.

Page 81: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 77

VI.2.1. Result from AMS • Total effective strain • Freudenthal • Cookcroft-Latham

VI.2.2. Result from SMS • Total effective strain • Effective strain rate • Pressure • Contact node • Vx

• Vy

• Vz

• Vθ

• Vr

Page 82: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 78

VI.3. Verification of Result

VI.3.1. Nodal solution The various result of each mesh-systems can be verified by Contour window. The default issue is the total effective strain as shown Fig. If you want to change issue, select other issue in combo-box.

Fig.VI.3.1 Total effective strain on AMS

For examples, If you want to change issue to Freudenthal, select Freudenthal in combo-box as shown below figure.

Fig.VI.3.2 Information bar

Then the contour of workpiece will be change like below figure.

Page 83: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 79

Fig.VI.3.3 Freudenthal on AMS

The contact node of workpiece on SMS is shown as the following figure.

Fig.VI.3.4 Contact node on SMS

VI.3.2. Creating sliced workpiece Open *.RSF file format

If you don’t know section number you want to see,

Page 84: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 80

Click the Filter icon and Select Polygons&Elements and Solid Section.

Set Selection filter

Page 85: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 81

Click the Wireframe icon , you can see the workpiece as wireframe. Then move the mouse close to the cross section you want to see, the selected cross section will be high light. You can see section number (red box) at property bar

highlighted cross section

Select Post process -> Create Sliced Workpiece

Page 86: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 82

Insert the cross section number at Starting section and Ending section.

(Ending section number is always bigger than Starting section number.)

Fig.VI.3.5 Create Sliced Workpiece

You can see the cross section you want to see.

Fig.VI.3.6 Sliced workpiece

Page 87: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 83

VI.3.3. Creating flow-net For initial setting of flow net, click Post Process -> Flow net (see Fig.VI.3.7)

Fig.VI.3.7 Settings of flow-net, Step1[Primary Layer]

At the result of SMS or AMS, you can verify the flow-net. The initial net can be rectangular form. You can specify the start and end step and the density of initial net form. Each parameter, number of horizontal and vertical divisions, can't exceed 100(see Fig.VI.3.8).

Fig.VI.3.8 Settings of flow-net Step2[Primary Layer]

In order to see the flow-net, change the layer to Flow-net layer(Fig.VI.3.9), and then you can see Initial netted section.(see Fig.VI.3.10)

Fig.VI.3.9 Flow-net layer [Flow net Layer]

Page 88: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 84

Fig.VI.3.10 Initial netted section[Flow net Layer]

Page 89: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 85

VI.3.4. Animation The workpiece and flow-net is supported the animation that the step is updated to next in regular order. You can change the refresh speed which is milli-second.

Fig.VI.3.11 Setting of refresh speed

If you click Start from Animation menu, the animation will be started. Also you can pause and stop the animation, and ESC key will work as stopping the animation.

Fig.VI.3.12 Starting menu of animation

VI.4. Making a rendered results

VI.4.1. Changing Contour Mode SHAPE-RR supports various contour styles - shade, filled polygon, filled element and line strip mode. You can verify results with it. To change the contour mode, select proper contour style in Contour from Post-process menu.

Fig.VI.4.1. Contour styles

The description of each contour style icons is shown in Table.VI.4.1. And Fig.VI.4.2~6 show features applied contour styles respectively.

Page 90: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 86

Table.VI.4.1. Description of contour styles

Tool

bar

Command

Description

Shaded Contour

The calculating results will be in transit homogeneously

Filled Polygon

The results will be displayed in filled polygon

Line Strip

The results will be seen in contour lines, which interpolate the node values.

Filled Element

The simulation results will be seen in a element

Hide Contour

The sheet will be seen in hide contour

Contour Properties

Changing pattern of contour properties

Fig.VI.4.2. Shade mode

Fig.VI.4.3. Filled polygon mode

Page 91: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 87

Fig.VI.4.4. Filled element mode

Fig.VI.4.5. Line strip mode

Fig.VI.4.6. None mode

Page 92: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 88

VI.4.2. Changing Contour Properties The contour properties can be changed to your preference. To change the properties, click the Contour Properties. In this dialog box, you can modify levels of contour and define colors of contour levels.

VI.4.2.1. Contour Levels You can change levels of contour and other properties. It is noted that the large contour levels will consume the system resource for rendering features. So you should select the number of contour levels properly.

Fig.VI.4.7 Contour Levels in Contour Properties

• Number of contour levels(2-50) : The displaying color will be in transition from the max. value to min. value by the number of contour levels in the part.

• Regular Interval The values between the max. value and min. value will be divided by equal length.

• Restore Bounds Resetting the max. value and min value as default value.

• Exponent notation If the blank is checked, the value will be expressed in exponent.

• Show positive sign If it is checked, the value will be assign by plus or minus.

• Position of the decimal point If the blank is filled in 2, the number of value before exponent is two.

• Position of the multiplier If the blank is filled in 3, the number of power is three.

For examples, on Filled Polygon mode, if you change the number of contour levels to 30, from 8, the contour will be changed as shown below figures.

Page 93: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 89

Fig.VI.4.8 Contour levels 8

Fig.VI.4.9 Contour levels 30

VI.4.2.2. Color Palettes You can change type of contour color and define each color of contour levels.

Fig.VI.4.10 Color Palettes in Contour Properties

• Type Setting the type of contour palette

(There are “Custom”, “grayscale”, “RGB”, “MBYR” and “YRB” type in the combo-box) • Contour Preview

Previewing bar of current contour • Palette List

Select a color

Page 94: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 90

• Insert after Inserting the user color after the currently highlighted color.

• Modify Modifying the currently highlighted color.

VI.5. Plotting Curve From Simulation Results SHAPE-RR supports the plotting curve from simulation results. You can verify and compare the results by graph.

VI.5.1. Tools For Plotting A Curve

Fig.VI.5.1 Tools & Filters

Table.VI.5.1. Description of Tools & Filters

Tool

bar Command Description

Change picking mode to entity selection

Change picking mode to entity selection

Change picking mode to object selection

Change picking mode to object selection

Circular selection

Select the points along the circular direction

Create groupCreate group for current selection

Create curve from group

Create curve data from selecting group

Curve plotting

Display curve properties in graph

Page 95: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 91

VI.5.2. Curve Plotting In Detail

If you want to select object(s) that you need, click the Filter icon. Then, the Filtering window appears as below

Fig.VI.5.2(a) Before Selecting Fig.VI.5.2(b) After Selecting

Select the object that you want to select in Object List and click the icon. Selected object moves from

“Object List to Selectable. If you want to select all objects in Object List, click the icon. (No need to

select any object in Object List). The selection of object(s) can be deselected by clicking the icon or

icon.

VI.5.2.1. Create Group

To create the nodes group, you must select nodes. There are two methods selecting nodes. One is to select nodes you want. The other is to use the function that selects all circular nodes for picked only one node. To use the latter case, click Circular Selection.

Note) Enter Esc key to cancel the command and press Shift and pick the one node on the other pass for continuous select.

Fig.VI.5.3 Selected nodes with Circular Selection command

Page 96: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 92

To create group click the Create group from Post-process as presented in Fig.VI.5.4

Fig.VI.5.4 Post-Process menus

Then the Create Group window will appear as presented in Fig. VI.5.5. If you want to rename the group, you write down the name in the text box and then click the Create command button.

.

Fig.VI.5.5 Create Group window

Page 97: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 93

VI.5.2.2. Create Curve from Group

To create curve for group, click the Create Curve from Post-process menu. Then Group/Curve Manager dialog box will appear as shown in Fig.VI.5.6. Note) If there is no groups have been created, this icon is not active.

Fig.VI.5.6 Group/Curve Manager

• Group: There are group-names and its type(s) you have created in this part of window.

• X-axis and Y-axis: You can select the X-axis and Y-axis of the curve

• Curve preview: The curve is shown whenever you select the X-axis and Y-axis

• Remove Grp., Add Curve and Remove Crv. Command button : You can remove the existing groups, add the curve and remove the existing curves by using this command buttons

• Curve List: The created curve is shown in this part of windows Then Select the X-axis and Y-axis data as presented Fig.VI.5.6 and check the curvet. After that, click the Add Curve command button. A Create New Curve window will appear as presented in Fig. VI.5.7.

Fig.VI.5.7 Create New Curve

Where, if you want to rename the curve title, you can write down the title in text-box in the Create New Curve

Page 98: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 94

window and then click the Create command button.

VI.5.2.3. Curve plotting

If you have created curves from the group you selected, you can verify and compare curves by Curve Plotting from Post-process menu. Click Curve Plotting, then Curve Plotting window will appear as presented in Fig.VI.5.8.

Fig.VI.5.8 Curve Plotting

You can compare the curves as selecting several curves as shown in Fig.VI.5.9.

Fig.VI.5.9 Comparison of curves

Page 99: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 95

VI.5.2.4. Using Tool bar in Curve Plotting window Curve Plotting has the tool-bar. With tool-bar, you can manipulate the curve and verify the result with various functions.

Fig.VI.5.10 Toolbar in Curve Plotting

Table.VI.5.2. Description of Curve Plotting toolbar

Tool

bar Command Description

Open chart Open an existing chart

Save chart Save current chart

Copy to

Clipboard

Copying to clipboard as a bitmap, metafile, text(data only) and OLE object

Gallery Selecting the type of curve such as “Line”, “Area” and “Step” ,etc…

Color Select a color

Vertical grid Grid across the vertical direction

Horizontal grid Grid across the horizontal

dirction

Legend box Legend box

Data editor You can show the data by

clicking this icon

Properties Change the properties of curve

3D/2D Switching the 2D and 3D curve

Rotate If you select 3D curve, you can

rotate the curve.

Z-Clustered Display series in different rows

along the z-axis

Zoom Zooming window

Print preview Print preview

Print Print current graph

Tools Tools which can used

Page 100: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 96

VI.6. Report Generation SHAPE-RR supports the generation of report. The whole information of simulation is exported to the file which is formatted HTML currently. The report can be also generated while pre-processing. In this case, only the pre-processing data will be exported.

Fig.VI.6.1 Tool menu

To generate the report, run Report Manager by clicking Report generate from the Tool menu. Then you can see the below figure.

Fig.VI.6.2 Report Manager

• Project info: Project title, Assignment, Executant, Date for simulation

• Project summary: Not available

• Workpiece info: Ring geometry, Information of sectional mesh and boundary condition

• Roll geometry: Sectional profile of roll, Velocity condition of roll

• Material properties: Flow stress equation, Material properties

Page 101: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 97

• Process conditions: Process condition of simulation

• Analysis conditions: Stopping criteria of simulation

• Result of solving: Information of start and end step

• Additional comment: Referred comment

• Software Info: Version information of SHAPE-RR

The Additional comment is user's referred comment. You can write the comment by clicking Write button as shown in below figure.

Fig.VI.6.3 Comment

Fig shows that the generated report is opened by internet browser.

Fig.VI.6.4 Report with internet browser Customizing Features

It is possible to change rendering option and surface refinement. Customized style option changes only physical appearance, not result.

Page 102: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 98

Fig.VI.7.1 Feature menu

VI.6.1. Rendering options VI.6.1.1. Appearance

The color of main window and each object can be changed using packaged color set or selecting the color of each objects.

• Using packaged color sets

Fig.VI.7.2 Selecting the color set

Page 103: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 99

Select the black set in the color scheme, and click the Apply. The main window and all objects colors will be changed under the pre-defined color set as showing Fig.VI.7.3

Fig.VI.7.3 Changing the color set to black set

• Changing the color of each item Select the item in the combo box, and select the color.

Fig.VI.7.4 Selecting object

Fig.VI.7.5 Standard colors

Page 104: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 100

Fig.VI.7.6 Other colors

Fig.VI.7.7 Changing color of roll skin

VI.6.1.2. Light properties

If the Light option in Render from Feature menu is used, the appearance of object is recognized exactly. The light position can be changed by the input of position coordinates.

Fig.VI.7.8 Render toolbar

Fig.VI.7.9 Change of the light position

Page 105: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 101

• Light position The coordinate of light position is independent to object coordinates. It is only determined to screen coordinates as shown Fig.VI.7.9. If the coordinates of light position have only Z-axis value, the light source is located at front (or back) as shown Fig.VI.7.11. The Fig.VI.7.12 shows the case of light position (0, 10000, 0).

z

y

x

Fig.VI.7.10 The coordinate system of light position

Fig.VI.7.11 Light position (0, 0, 10000) Fig.VI.7.12 Light position (0, 10000, 0)

• Degree of shininess It is to control the shininess of the light. If the degree of shininess is increased then the light is concentrated upon the normal plane of the object.

Page 106: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 102

VI.6.2. Surface refinement The feature of roll geometry is depicted by the synthesis of segments of straight line or plane. The large amount of segments is required the expensive computational resource to render the feature. To avoid high-priced rendering, it is recommended that the number of segments should be given properly.

Fig.VI.7.14 Surface refinement

Note) This option is available for only displaying the roll in the window.

VI.6.2.1. Arc depiction

L θ

Fig.VI.7.15 The segment of arc depiction

• Maximum length(L) of dividing segments It determines the maximum length to divide the arc.

• Minimum angle(θ ) of dividing segments It determines the minimum angle to divide the arc.

Page 107: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 103

VI.6.2.2. Revolution The number of subdivisions along the roll axis It determine the number of divisions along the roll axis to revolute the roll description.

Fig.VI.7.16(a) The case of 15 divisions (b) The case of 60 divisions

Page 108: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 104

VI.7. Image Capture

VI.7.1. Specification of region to be exported To capture the image on screen, click Capture from Tool menu. You can see Screen Capture dialog box.

Fig.VI.8.1 Tool menu

Click Start drag to specify the region which is to make export.

Fig.VI.8.2 Screen Capture

In the screen, if you push down the left button of mouse, the region will be specified with a rectangular mark until you push up the left button of mouse as shown in Fig.VI.8.3.

Fig.VI.8.3 Specification of region

If the region is specified, then Screen Capture dialog box will appear with a picture of specified region automatically as shown in below figure.

Page 109: RR Manual All

S H A P Eolutions for ighly dvanced rocess ngineering

VI. Post-processing 105

Fig.VI.8.4 Preview of captured image

To export the image to file, click ‘Save’ button in Screen Capture dialog box. Then you can see Save As dialog box. Currently you can export to the file which is bitmap image type. Click Save button after you define the name of image.

Fig.VI.8.5 Save As window

VI.7.2. Full Screen Capture To capture the whole screen, click Full image button in Screen Capture dialog box. For examples, as the screen of SHAPE-RR is like Fig.VI.8.6, if you click Full image then the whole screen will be shown in Preview as shown Fig.VI.8.7. To save in file, click ‘Save’ button.

Fig.VI.8.6 Main window

Fig.VI.8.7 Preview of full image