Deform 3d Tutorial [upd]

DEFORM-3D is a powerful finite element method (FEM) system used to simulate complex 3D metal forming, machining, and heat treatment processes. This guide outlines the standard workflow for setting up and running a professional simulation. Scientific Forming Technologies Corporation 1. Pre-Processor: Problem Setup

The pre-processor is where you define the physical parameters of your simulation. Slideshare DEFORM-3D - Scientific Forming Technologies Corporation

5. Simulation controls

• Step setup
  • Total stroke: 15 mm (50% height reduction).
  • Number of steps: 50.
  • Step increment: 0.3 mm (or solution steps advanced by time).
• Save steps: every 5 steps.

Part 7: Optimizing Your Workflow (Pro Tips)

• Keyboard Shortcuts (Post):
  • F = Fit view
  • R = Rotate
  • S = Shade/Solid
  • W = Wireframe
• Batch Simulation: Use the "Queue" manager. Setup 5 different temperatures (700C, 800C, 900C) and run them overnight.
• DXF vs STL: Always import dies as .STL in binary format. Never use .STEP for Deform 3D (it triangulates poorly). Use high resolution when exporting from SolidWorks/Inventor.
• Symmetric Modeling: If your billet is round and the die is round, cut a 1/4 wedge (90 degrees). Set "Symmetry" boundary conditions. This runs 4x faster than a full model.

Part 2: Your First Simulation – A Simple Upsetting Test

The "Hello World" of forging simulation is the Upsetting Test. You take a cylinder, squeeze it between two flat dies, and observe the barreling effect. deform 3d tutorial

2. Die Stress Analysis

To see if your forging die will crack under pressure.

• Workflow: Run a standard simulation -> Save the final step -> Create a "Die Stress" simulation -> Import the load from the plastic object onto the rigid die (which you now switch to elastic).

Step 6: Inter-Object Relationships (Contact)

DEFORM needs to know what touches what.

1. Click "Inter-object" (Handshake icon).
2. Object 2 (Top Die) to Object 1 (Billet):
   • Friction: Shear (Best for bulk forming).
   • Friction coefficient: 0.12 (for cold forging with lubrication).
3. Object 3 (Bottom Die) to Object 1 (Billet):
   • Same settings.

Common Mistakes & Troubleshooting

| Issue | Likely Cause | Solution | | :--- | :--- | :--- | | Simulation crashes immediately | Interference (dies penetrating billet at Step 0) | Move the dies apart in CAD, or use Inter-object -> Positioning to separate them. | | Mesh tears apart / Negative Jacobians | Step size too large. | Halve your Step size per stroke (e.g., from 0.075mm to 0.0375mm). | | Load is 1,000,000 tons (unrealistic) | Material is defined in tons/mm² but your units are wrong. | Check Simulation Controls -> Units before running. | | Billet flies away | Forgot to set friction. Frictionless metal slides infinitely. | Set Friction: Shear 0.12. |

Step 5: Interactions (Friction)

This is the critical step that separates good simulations from bad ones. DEFORM-3D is a powerful finite element method (FEM)

1. Inter-Object Relationships: You must define how the dies touch the billet.
2. Friction: Select the contact between the Top Die and Billet. Choose Shear Friction (common in bulk forming) or Coulomb Friction (common in sheet metal). A friction coefficient of 0.12 to 0.3 is typical for cold forming with lubrication.
3. Contact Tolerance: Set the tolerance so the software knows when two parts are touching.

1. Heat Transfer (Coupled Analysis)

If you are forging steel at 1200°C (red hot), the die sucks heat out rapidly.

• How to: In Step 1 (New Problem), choose Deformation & Heat Transfer.
• You must assign thermal properties (conductivity, specific heat) to all objects, including dies.