DEFORM Manual – Ring Rolling & Shape_Rolling & COGGING LAB

Ring Rolling System manual
Project based
The Ring Rolling Template is project based in which each simulation will be associated with a project directory. A project can consist of a single operation.
User interface
The interface is an innovative mixture of an open system and guided user interface. If the user desires, navigation can be sequential, via a list of menus to construct a simulation;alternatively, the user can access menus in any sequence by selecting any item in a list.The navigation within this program is made through a single window. Tabs and buttons are available to direct the user to various points in the program including project set up,running the simulation and viewing the results.

Shape Rolling System Manual
Project based
The Shape Rolling Template is project based in which each simulation will be associated with a project directory. A project can consist of a single operation or contain multiple operations that occur on a single rolled stock. Each operation can be either a change in roll geometry, roll gap, and roll speed, workpiece orientation or a heat transfer operation.
User interface
The interface is an innovative mixture of an open system and guided user interface. If the user desires, navigation can be sequential, via a list of menus to construct a simulation data; alternatively, the user can access menus in any sequence by selecting any item in a list. Running the simulation and Post-Processing the results is carried out via the standard DEFORM™-3D features.

RING ROLLING LAB 
Problem Setup
Thermal Calculations
Workpiece Shape
Workpiece Geometry
Workpiece Mesh Generation
Material Definition Window
Driving Roll Geometry
Driving Roll Position
Driving Roll Movement Definition
Pressure Roll (Mandrel) Geometry
Pressure Roll (Mandrel) Position
Pressure Roll (Mandrel) Movement Definition
Inter Object Definition
Stopping Controls
Step Controls

SHAPE ROLLING TEMPLATE (ALE)
Creating a New Problem
Layout of Shape rolling template
Defining the Rolling Process
Roll Pass Design Setup
Defining Rolls
Defining Geometry for Roll
Defining Material & BCC for Roll
Defining Angular Movement for Roll
Defining Workpiece/Stock.
Defining Workpiece/Stock Geometry
Generating Mesh for Workpiece/Stock
Defining Material & BCC for Workpiece/Stock
Defining Inter-Object Relations
Running the Simulation and Post-Processing

SHAPE ROLLING TEMPLATE (LAGRANGIAN)
Creating a New Problem
Layout of Shape rolling template
Defining the Rolling Process
Defining Roll Pass Design
Defining Roll
Defining Top Roll
Defining 3D-Geometry and Mesh for Top Roll
Defining Material & BCC for Top Roll
Defining Angular Movement for Top Roll
Defining Bottom Roll
Defining 3D-Geometry and Mesh for Bottom Roll
Defining Material & BCC for Roll
Defining Angular Movement for Roll
Defining Tables
Defining Tables (back)
Defining Table Geometry
Defining 3D- Geometry for the Table
Generating Mesh for the Table
Defining Material & BCC for Table (back)
Defining Tables (front)
Defining Table (front) Geometry
Defining 3D- Geometry for the Table (front)
Generating Mesh for the Table (front)
Defining Work piece/Stock
Defining Work piece/Stock Geometry
Generating Mesh for Work piece/Stock
Defining Material & BCC for Work piece/Stock
Defining Pusher
Defining Geometry for Pusher
Defining Mesh for Pusher
Defining Mesh for Pusher
Defining Material & BCC for Pusher
Defining Movement for Pusher
Defining Object Positioning & Inter-Object Relations
Defining Step Controls For Pass1
Defining a Second Pass
Defining Inter-pass heat transfer
Defining a Third Pass
. Defining Main Rolls
. Defining Side Rolls
. Defining Pusher Movement
. Object Positioning for Pass 3
Defining a Fourth Pass
Exiting Shape Rolling Wizard
Running the Simulation and Post-Processing

DEFORM 3D Cogging Lab
Introduction
Problem Setup
Generating Simulation Data
Running a Simulation
Material Data

Cogging wizard is used to generate the master files and the billet, die and manipulator keyword files to run a typical cogging simulation.

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