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Open Die Forging Analysis Tutorial

The document outlines a tutorial for performing a 2D plane strain analysis of open die forging on an annealed copper block, detailing the necessary steps and material properties. It includes a problem statement requiring the determination of forging pressure to reduce the block's height by 25%. Additionally, it covers the learning outcomes related to modeling, assigning constraints, and interpreting simulation results.

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lntjugal
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9 views6 pages

Open Die Forging Analysis Tutorial

The document outlines a tutorial for performing a 2D plane strain analysis of open die forging on an annealed copper block, detailing the necessary steps and material properties. It includes a problem statement requiring the determination of forging pressure to reduce the block's height by 25%. Additionally, it covers the learning outcomes related to modeling, assigning constraints, and interpreting simulation results.

Uploaded by

lntjugal
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd

Manufacturing Processes Lab

Tutorial 1

Personalized Learning
WILP

Open Die Forging


Problem Statement

Perform a 2D plane strain analysis of the open die forging of an annealed copper
rectangular block as shown in diagram below:
Forming Pressure

Upper Die

Block

Lower Die

Determine the forging pressure required to reduce the height of the block by 25%. The bar
has a rectangular cross section of 32 mm height and 40 mm length.
Material properties Based on Experiments
Tool Steel for Die

• E = 210 GPa, ν = 0.27, σy = 250 MPa, Tangent modulus = 1450 MPa

Annealed Copper
• E = 110 GPa, ν = 0.34, σy = 33 MPa, Tangent modulus = 167 MPa.

Aluminium Alloy
• E = 70 GPa, ν = 0.33, σy = 276 MPa, Tangent modulus = 562 MPa.

Magnesium Alloy
• E = 45 GPa, ν = 0.35, σy = 138 MPa, Tangent modulus = 633 MPa.

Steel
• E = 193 GPa, ν = 0.35, σy = 207 MPa, Tangent modulus = 692 MPa.
STEPS
• Step 1: Create a working directory @ cloud desktop

• Step 2: Open the Ansys workbench software

• Step 3: Open Analysis System: Static Structure

• Step 4: Create/Import Geometry

• Step 5: Set material property

• Step 6: Generate Mesh

• Step 7: Add constraints( Boundary & Load conditions)

• Step 8: Solve

• Step 9: Result interpretation

• Step 10: Validation


LEARNING OUTCOME

• How to model the geometry and assigning the material

• How to Assign constraints

• How to Assign real loading conditions

• How to interpret the simulation results

• Validating numerical results with analytical solution


Validation

Pressure required for the deformation of 25% for Annealed Copper

P = Y1 Property
Y0 (MPa)
Value
33
Where, Y1 = Resultant Yield Stress = Y0 + Etan ε (mm) 32
(mm) 24
Y0 = Yield Stress, Etan = Tangent Modulus, ε = Strain ε 0.287
Etan (MPa) 167
Strain (ε) = ln
Y1 80.93
µ 0 0.05
B (mm) 40 40
P(MPa) 80.93 87.96

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