Rathmann - 4th ICFG Workshop

4th ICFG Workshop on Process Simulation
in the Metal Forming Industry
Development of a Technological
Processor 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
PtU, Rathmann
Produktionstechnik und Umformmaschinen

Technische Universitt Darmstadt
Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing. P. Groche
10/06/2004 _tr_1.ppt
Outline
Overview of the rotary swaging process
Process-Simulation
Experimental Verification
Technological Processor
PtU, Rathmann

10/06/2004 _tr_2.ppt
Introduction - Rotary Swaging
source: Felss
Principle
Components
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.
PtU, Rathmann

10/06/2004 _tr_3.ppt
Typical Components
Homokinetic joint
Drive shaft
source: Felss
source: HMP
Rotary Swaging an efficient

cold forming process for forming
tubes and bars
Hinge shaft
Gearshaft
source: Felss
PtU, Rathmann
source: HMP
10/06/2004 _tr_4.ppt
Rotary Swaging Process principle
Presentation as a sequence
PtU, Rathmann

10/06/2004 _tr_5.ppt
Process Variations
Infeed-swaging
Recess-swaging
without
mandrel
with
mandrel
PtU, Rathmann

10/06/2004 _tr_6.ppt
Problems and Objectives
The process planning has a crucial influence on the economic efficiency of the
process
Process planning
9
9
9
9
Planning of stages
Die construction
Setup and adjustment
Die changes (possibly)
Common
Problems
Based on the knowledge of the staff members
knowledge
Loss of knowledge if staff leaves employment
PtU, Rathmann

10/06/2004 _tr_7.ppt
Problems and Objectives

Technological
Problems
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
OBJECTIVES
Analysis of the rotary swaging process by FEA

Simplification of the use of FEA by a technological
processor (as interface)
PtU, Rathmann

10/06/2004 _tr_8.ppt
Postulated Process Planning
Process Planning assisted by FEA
Drawing of
workpiece
Tool
construction
Modelling
NOK
(up to now)
Simulation
New parameters
OK?
Analysis of the results
Try-Out
Yes
PtU, Rathmann

10/06/2004 _tr_9.ppt
Process-Simulation
PtU, Rathmann

10/06/2004 _tr_10.ppt
FEA-sequence up to now
THE MARC SYSTEM
Steps
Time requirements
START
MSC.Marc
Mentat
Preprocessing
MSC.Marc
Analysis
MSC.Marc
Mentat
Postprocessing
Subroutine
80160 h
5-500 h
5h
END
FE-Knowledges required in
all steps
PtU, Rathmann

10/06/2004 _tr_11.ppt
Problems of simulation of rotary swaging processes

Particularities concerning the simulation of rotary swaging processes
Incremental forming operation with 100 to 300 cycles
Tool-separation in every cycle
3D-Modelling required
die
workpiece
3D-Modelling High element numbers

Representation of complex tool kinematics
Contact changes in a high frequency
High numbers of iterations
problems
rdie > rwp
Convergence
Computing time
PtU, Rathmann

10/06/2004 _tr_12.ppt
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
Advantages
No rigid body movement of the workpiece
Simplified evaluation
Easier implementation of analysis modules in the
technological processor
PtU, Rathmann

10/06/2004 _tr_13.ppt
Use of cyclic symmetry

4-fold segmented tools Quarter-model
Reducing element numbers
Possibility to reduce computing time (saving of time ~ )

Corresponding results (difference < 0,04%)
PtU, Rathmann

10/06/2004 _tr_14.ppt
Examination of convergence
Influence of spatial discretisation
Max. radial force Frad
Maximalkraft
radial
force
Radialkraft
[kN] [kN]
700
2D
600
Exp.
3D
500
400
300
200
100
0
2D Grob
2D Mittel
2D Fein
3D Grob
3D Mittel
3D Fein
Experiment
grid
Netz
Representation of die movement
T
TDC
BDC
Objective: Reduction of element- and increment numbers

PtU, Rathmann

10/06/2004 _tr_15.ppt
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)
Technological quantities
Rotational speed ni + Stroking frequency fsw Angle of rotation per pass P
Rate of feed + Stroking frequency fsw Feed per pass vx,P

PtU, Rathmann

10/06/2004 _tr_16.ppt
Influence of the technological quantities
Evaluation by comparing the maximum

occuring axial and radial forces
Einfluss des Drehwinkels pro Hub

Influence
of angle of rotation per pass
ESoD; v
vrad/Hub=0,0074=konst.
RSwoM;
rad/pass=0,07=const.
120
Kraft [kN] [kN]

Force
Kraftverlauf
beim
Vorschubrundkneten
Force
progression
(Feed swaging
ohne without
Dorn mandrel)
150000
Frad [N]
125000
100000
100
80
Fradmax [kN]
60
Faxmax [kN]
40
75000
20
50000
max.
126.1
[kN]kN
max.Radialkraft:
radial force:
126,1
25000
0
0
10
20
30
40
50
3D Simulation
2,4
path
[mm] 60
Weg [mm]
3,36
4,8
5,6
9,06
13,2
18,85
22
pro Hub per

[]
AngleDrehwinkel
of rotation
pass []
15000
Fax [N]
12500
Einfluss
des Axialvorschubes
Influence
of axial
rate of feed per pass
VSoD
(Drehwinkel
Hub ==12
= konst.)
FSwoM;
Ppro
= 12
const.
10000
7500
5000
120
0
0
10
Maschinendaten
Process
Parameters
20
30
Technologische
Gren
Technological
Quantities
Knetfrequenz:
[Hz]
Drehwinkel
13.6 []
Swaging Frequency: 30 30 Hz
Angle
of rotationpro
perHub:
pass: 12
Vorschubgeschwindigkeit:
0.05m/min
[m/min] AxialAxialvorschub
0.03mm
[mm]
Axial rate of feed:
0,164
feed per pass:pro Hub: 0,09
Drehvorschub:
Rotating speed:
60 68 [1/min]
1/min
40
50
Kraft [kN]
Force
[kN]
140
max.
Axialkraft:
7.1 [kN]
max.
axial force:
7,1 kN
2500
path
[mm]60
Weg [mm]
Simulationsspez.
Angaben
FE-specific
quantities
HSS-Diskretisierung:
Increments
per pass: 77 [Inc/Hub]
Gittertyp: G2
Grid-type:
G2
T:\Rundkneten\Vorschub\180703\5\fort.25.
100
80
Fradmax [kN]
Faxmax [kN]
60
40
20
0
0,012
0,017
0,028
0,048
0,091
0,167
0,278
Hub [mm]
AxialAxialvorschub
feed per pro
pass
[mm]
PtU, Rathmann

10/06/2004 _tr_17.ppt
Influence of the technological quantities
Evaluation by comparing the maximum

evaluated wall thickness (in the zone of
calibration)
3.3
3.2
14
13
max. Wandstrke im
15
3,34
3,32
3,3
3,28
3,26
3,24
2,4
4,8
5,6
9,06
13,2
18,85
22
Angle of rotation per pass []
12
11
3.1
3,36
Drehwinkel pro Hub []
10
9
0
10
20
30
40
3D Simulation
Maschinendaten
Process
Parameters
Technologische
Gren
Technological
Quantities
50
60
70
80
Lnge [mm]
path [mm]
Simulationsspez.
Angaben
FE-specific
quantities
Drehwinkel
12.00 []
Knetfrequenz:
30
Swaging Frequency: 30
Hz[Hz]
Angle
of rotationpro
perHub:
pass: 12
Increments
0.1638
0.09
[mm]
Gittertyp: G2
Axial rate of feed:
0,164
m/min[m/min]
AxialAxialvorschub
mm
Grid-type:
G2
Drehvorschub:
[1/min]
Rotating speed:
60 60 1/min
T:\Rundkneten\Vorschub\040503\3\okr_dispyz.
max. Wandstrke im
Max.Kalibrierbereich
wall thickness
[mm]
[mm]
3.4
16
Radius [mm]
wallthickness [mm]
Wandstrke [mm]
3.5
Max. wall
thickness [mm]
Kalibrierereich [mm]
Wandstrkeverlauf
Course ofbeim
wall Vorschubrundkneten
thickness
(Feed swaging
without mandrel)
ohne Dorn
Einfluss
des Drehwinkels
pro Hub
Influence
of angle
of rotation
per pass
/Hub
= 0,0074mm = konst.
ESoD; v rad
/pass=0,07=const.
RSwoM;
vrad
Einfluss des Axialvorschubes

Influence
of axial rate of feed per pass
VSoD (Drehwinkel pro Hub = 12 = konst.)
FSwoM; P = 12 = const.
3,38
3,36
3,34
3,32
3,3
3,28
3,26
0,012
0,017
0,028
0,048
0,091
0,167
0,278
Axial rate of feed per pass [mm]

Axialvorschub pro Hub [mm]
PtU, Rathmann

10/06/2004 _tr_18.ppt
Experimental Verification
PtU, Rathmann

10/06/2004 _tr_19.ppt
Possibilities of Verification
PtU, Rathmann
Grain structure
Geometry
Micro hardness
Plastic strain
Kraftverlauf beim Einstechrundkneten ohne Dorn
F rad [kN]
100
Forcemeasurement
75
50
25
0
-25
0
10
15
20
25
Zeit [s]
10
15
20
25
Zeit [s]
10
F ax [kN]
S
I
M
U
L
A
T
I
O
N
7.5
5
2.5
0
-2.5

Werkstoff: 16 MnCr5 (1.7131)
Knetfrequenz (IST): 33 Hz
Abmessungen (L/D/s)[mm] : 330/30/3
Abtastrate: 3 kHz
Bemerkung: :
Drehzahl Knetwelle : 110 1/min
E
X
P
E
R
I
M
E
N
T
Dateiname: V7_1.dat
10/06/2004 _tr_20.ppt
Metrology
Measurement of radial forces
Outer rotor
Base jaw with integrated

force transducers
Swaging shaft
Wireless transmission required Telemetry

(rotating swaging shaft)
High sampling rates due to high swaging
frequencies (100 ... 300 measurements/pass)
PtU, Rathmann
Front plate with adapted

telemetrical transmitter

10/06/2004 _tr_21.ppt
Metrology
Measurement of axial forces
clamping unit
Transmission of signals by wire

force transducer
PtU, Rathmann

10/06/2004 _tr_22.ppt
Results of measurements
Force
progression
swaging without
mandrel)
Kraftverlauf
beim (Recess
Einstechrundkneten
ohne
Dorn
F rad [kN]
100
75
50
25
0
-25
0
60
F_rad [kN]
50
F ax [kN]
10
10
15
20
3s
calibration
Einzelschlagdarstellung
F_rad Frate
Resolution
of single
strokes
rad (20 mm/min)
Radial
speed
7.5
25
time
Zeit [s]
fsw
2.5
40
30
-2.5
0
10
15
20
25
time
Zeit [s]
20
Werkstoff:
16 MnCr5
(1.7131)
Material:
16MnCr5
10
(actual): 33 Hz
Dimensions:
(D/L/Wt)[mm]
rate: 3 kHz
Abmessungen
(L/D/s)[mm]
: 330/30/3 330/30/3
Abtastrate: 3Sampling
kHz
Swaging
Bemerkung: : Drehzahl Knetwelle
: 110 shaft:
1/min 110 rpm
20.4
Werkstoff: 16 MnCr5 (1.7131)
PtU, Rathmann
Abmessungen (L/D/s)[mm] : 330/30/3
Bemerkung: :
Knetfrequenz
(IST): 33 Hz
Stroking
frequency
20.425
20.45
Dateiname: V7_1.dat
20.475
Zeit [s]
Knetfrequenz (IST): 33 Hz
Abtastrate: 3 kHz
Drehzahl Knetwelle : 28 1/min

Prof. Dr.-Ing. Dipl.-Wirtsch.-Ing.
P. Groche
Dateiname:
V1_2_a.dat
10/06/2004 _tr_23.ppt
PtU, Rathmann

10/06/2004 _tr_24.ppt
Technological Processor (TP)

What are the intentions?
To simplify the input of all necessary input data:
- Process parameters
- Tool parameters
- Semi finished product data
To carry out the simulation in background
To evaluate and represent the results:
- Forces
- Geometric parameters (diameter, elongation, course of wall thickness)
- Parameters of forming technology (stress, strain)
Main objective:
To allow 3D-FEA of rotary swaging processes
for normal users without FE-knowledges
PtU, Rathmann

10/06/2004 _tr_25.ppt
Structure of the Technological Processor

START
technological
data
Iterative Optimizer
data base
CAD-system
geometrical
data
Preprocessor
input file
Compiler for input file
FEprogram
Postprocessor
output/ result file
Evaluation and representation

of the results
no
OK?
yes
END
PtU, Rathmann

10/06/2004 _tr_26.ppt
Programming-layout of the TP
FE-Program
MARC/MENTAT
Parameter entry
Programming languages:
Visual Basic (VB)
Visual Basic for
Applications (VBA)
PtU, Rathmann
Compiling and editing of

routines
procedures and
auto sequences
Automatic modelling

10/06/2004 _tr_27.ppt
Entry masks
Selection of the process variant
Input of process-parameters
PtU, Rathmann

10/06/2004 _tr_28.ppt
Entry masks
Input of tool parameters
PtU, Rathmann

10/06/2004 _tr_29.ppt
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.
PtU, Rathmann

10/06/2004 _tr_30.ppt
Special entry masks
FEA-specific
details
coarse
PtU, Rathmann
middle
Standard-grid
smooth
10/06/2004 _tr_31.ppt
Special entry masks
Single stroke discretisation
PtU, Rathmann

10/06/2004 _tr_32.ppt
Special entry masks
Storage of the results
Reduction of the amount of data

(storage-saving).
Not for all increments a result file is
written.
Remark to the special entry masks

these masks are provided for the advanced user
they normally are skipped
PtU, Rathmann

10/06/2004 _tr_33.ppt
Evaluation masks
Evaluation of the course of forces
Choose the file to be evaluated
Kraftverlauf
beim
Vorschubrundkneten
Force
progression
(Feed swaging
ohne without
Dorn mandrel)
150000
Frad [N]
125000
100000
75000
50000
max.
126.1
[kN]kN
max.Radialkraft:
radial force:
126,1
25000
0
0
10
20
30
40
50
3D Simulation
path
[mm] 60
Weg [mm]
15000
Fax [N]
12500
10000
7500
5000
max.
Axialkraft:
7.1 [kN]
max.
axial force:
7,1 kN
2500
0
0
10
Maschinendaten
Process
Parameters
20
30
Technologische
Gren
Technological
Quantities
Knetfrequenz:
[Hz]
Drehwinkel
13.6 []
Swaging Frequency: 30 30 Hz
Angle
of rotationpro
perHub:
pass: 12
0.05m/min
[m/min] AxialAxialvorschub
0.03mm
[mm]
Axial rate of feed:
0,164
Drehvorschub:
Rotating speed:
60 68 [1/min]
1/min
PtU, Rathmann
40
50
path
[mm]60
Weg [mm]
Simulationsspez.
Angaben
FE-specific
quantities
Save as:
Increments
Gittertyp: G2
Grid-type:
G2
T:\Rundkneten\Vorschub\180703\5\fort.25.

10/06/2004 _tr_34.ppt
Evaluation masks
Evaluation of the course of wallthickness
Choose the file to be evaluated
Course of wall thickness
wallthickness [mm]
(Feed swaging with mandrel; D=18.5mm)
path [mm]
Process Parameters
Hz
Axial rate of feed:
0,164 m/min
Rotating speed:
60
1/min
PtU, Rathmann
Technological Quantities
Angle of rotation per pass: 12
Axial feed per pass:
0,09 mm
FE-specific quantities
Save as:
Increments per pass: 7

Grid-type:
G2

10/06/2004 _tr_35.ppt
Evaluation masks
Representation of parameters of forming technology
Vorschubrundkneten
ohne Dorn
Feed
swaging without mandrel
Equivalent von Mises Stress
Process
Parameters
Maschinendaten
Knetfrequenz:
30Hz[Hz]
Axial rate of feed:
0,164
m/min
0.5
[m/min]
Rotating speed:
60 681/min
Drehvorschub:
[1/min]
PtU, Rathmann
Max. Main Stress
Technological
Quantities
Technologische
Gren
pro pass:
Hub: 12
13.8 []
AngleDrehwinkel
of rotation per
Axial Axialvorschub
feed per pass: pro Hub:0,09
0.26mm
[mm]
FE-specific
quantities
Simulationsspez.
Angaben
7 [Inc/Hub]
Increments
per pass:
Save7as:
Grid-type:
G2
Gittertyp:G2

10/06/2004 _tr_36.ppt
Comparison FEA with/without technological processor

Conventional execution
Technological processor
START
MSC.Marc
Mentat
Subroutines
START
Preprocessing
120 h
5 min
Input via Entrymasks
60 h
MSC.Marc
10 min
Automated
evaluation via
Entry masks
END
MSC.Marc
250 h
MSC.Marc
Mentat
5h
Simulation
END
Postprocessing
Hardly no FEKnowledge required
FE-Knowledges required in all

steps
Time need reduced considerably !

PtU, Rathmann

10/06/2004 _tr_37.ppt
Summary
Examination of the rotary swaging process with the
help of 3D-FEA
Simplified use and integration of FEA in the process
planning
Reduction of the development time

I
g
ill n utin
e p
d
o m
m co
ed ced
v
o u
pr ed
Im R
Simulation
PtU, Rathmann
tim
m
of pro
th ve
e
kn d av
ow ai
led lab
ge ility
of an
th d
e ad
pr m
oc in
es ist
s ra
Technological processor
tio
n
Knowledge base
10/06/2004 _tr_38.ppt
Thank you for your attention!

Rathmann - 4th ICFG Workshop

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Rathmann - 4th ICFG Workshop

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4th ICFG Workshop on Process Simulation

in the Metal Forming Industry

Produktionstechnik und Umformmaschinen

Overview of the rotary swaging process

Produktionstechnik und Umformmaschinen

Introduction - Rotary Swaging

Produktionstechnik und Umformmaschinen

Rotary Swaging an efficient

Rotary Swaging Process principle

Produktionstechnik und Umformmaschinen

Produktionstechnik und Umformmaschinen

Problems and Objectives

Based on the knowledge of the staff members

Loss of knowledge if staff leaves employment

Produktionstechnik und Umformmaschinen

Problems and Objectives

Geometric changes in components cause long try-out-times

Analysis of the rotary swaging process by FEA

Produktionstechnik und Umformmaschinen

Postulated Process Planning

Process Planning assisted by FEA

Analysis of the results

Produktionstechnik und Umformmaschinen

Produktionstechnik und Umformmaschinen

THE MARC SYSTEM

Produktionstechnik und Umformmaschinen

Problems of simulation of rotary swaging processes

3D-Modelling High element numbers

rdie > rwp

Produktionstechnik und Umformmaschinen

Design of the Rotary swaging FEA-model

Representation of the tools by Rigid Bodies

Produktionstechnik und Umformmaschinen

Use of cyclic symmetry

Possibility to reduce computing time (saving of time ~ )

Produktionstechnik und Umformmaschinen

Representation of die movement

Objective: Reduction of element- and increment numbers

Produktionstechnik und Umformmaschinen

Stroking frequency fsw

Rotational speed ni + Stroking frequency fsw Angle of rotation per pass P

Rate of feed + Stroking frequency fsw Feed per pass vx,P

Produktionstechnik und Umformmaschinen

Influence of the technological quantities

Evaluation by comparing the maximum

Einfluss des Drehwinkels pro Hub

Kraft [kN] [kN]

pro Hub per

Produktionstechnik und Umformmaschinen

Influence of the technological quantities

Evaluation by comparing the maximum

Angle of rotation per pass []

Drehwinkel pro Hub []

Einfluss des Axialvorschubes

Axial rate of feed per pass [mm]

Produktionstechnik und Umformmaschinen

Produktionstechnik und Umformmaschinen

Produktionstechnik und Umformmaschinen

Werkstoff: 16 MnCr5 (1.7131)

Abmessungen (L/D/s)[mm] : 330/30/3

Drehzahl Knetwelle : 110 1/min

Base jaw with integrated

Wireless transmission required Telemetry