Altair RISE

A program to recognize and reward our most engaged community members

Nominate Yourself Now!

Analysis of a forging die

We are trying to analyze the failure of a forging die of a flange. The stationary die got cracked during the operation. So we are trying to find out a solution for the same. We are planning to use Altair HyperWorks to simulate this event.

Details of corresponding die:-

Die Material - DIN 2714

Hammer - 16 tonnes(42000 kgf)

Flange material - Titanium- 6Al-4V

Flange temperature - 870-950°c

Can you Please suggest the commonly used method used for Modelling and Analysis.

Thank You.

Find more posts tagged with

English

Radioss

Accepted answers

All comments

Altair Forum User

Hi Basil,

Is it failing at the first time of use? Or is it a failure after many cycles (more like fatigue)?.

Altair Forum User

Hi Basil,

Is it failing at the first time of use? Or is it a failure after many cycles (more like fatigue)?.

Yes, it cracked after the first hit.

let me know what type of meshing and analysis should I do?????

Altair Forum User

Hi Basil,

Crack propagation can be simulated in RADIOSS. We have a similar example file in Help, Ruptured Plate and also a tutorial is available shown crack propagation which can be accessed at: https://altairuniversity.com/conceptual-design-of-a-3-wheeler-motorbike/conceptual-design-of-a-3-wheeler-motorbike-stone-impact-simulation/

Meanwhile I will try to get some information specific to this project.

Altair Forum User

But in our case the work piece which is hitting the die , deforms to the flange shape and then the impact load is distributed to die. so in this case, the normal impact load may not be applicable directly to the die, since the force is first transmitted to the work piece and then to the die.

so how can we solve this ?????????

Altair Forum User

This is the image of our stationary die.

Unable to find an attachment - read this blog

Altair Forum User

Hi Basil,

Prior to failure model set up you need to model the forming simulation for this set up in HyperForm. Normally we model the die as rigid in HyperForm but in this case keep it as deformable.

Now take this model setup into RADIOSS and for the die material get all the failure parameters so that we can use /FAIL/JOHNSON card and can simulate this in RADIOSS.

Altair Forum User

Sir,

If you have any tutorials or videos related to simulation in HYPERFORM and RADIOSS please send them.

Altair Forum User

Hi Basil,

In Help you will get many tutorials on HyperForm. Also there are some video tutorials available in YouTube.

Altair Forum User

thank you sir......

Altair Forum User

Sir,

We couldn't simulate the model in hyperform since there are some problems regarding the normal and distance between punch and die. Can you please figure out the problems.

Here is the assembled model.

Unable to find an attachment - read this blog

Altair Forum User

Sir,

Here is the meshed model.

Unable to find an attachment - read this blog

Altair Forum User

Hi,

Please go through RD-E: 2600 Ruptured Plate in Example which shows modelling failure in RADIOSS and also go through RD-E: 4400 Blow Molding with AMS.

For the above mentioned examples, model files are available in your installation directory (<install_directory>/demos/hwsolvers/radioss/26_Ruptured_plate_____). please import them in HyperMesh and review the model.

For basic RADIOSS tutorials please go through the tutorials available in Help. Also you can refer https://www.youtube.com/watch?v=CxM52wP3_ew&list=PLQ7KUGFuVz4u5y3SvIEIU07427-gATaG6 which is a webinar on HyperMesh-RADIOSS interface.

Also go through https://www.youtube.com/watch?v=aDeNhQFvqjE&t=8s which shows setting up a simple impact analysis in RADIOSS.

Altair Forum User

Sir,

Here is the revised model.

Unable to find an attachment - read this blog

Altair Forum User

Hi Basil,

The model setup will be somewhat like this (Check the model file attached).

Provide the appropriate material for the components and the failure card (as in the example above) and try running.

Unable to find an attachment - read this blog

Altair Forum User

Thank you sir. We will work on it.