UPSETTING OF A CYLINDER

The process of setting up a finite element analysis for upsetting of a cylinder consists
of twelve (12) main stages:

1. Creating the process – where the process of upsetting will be created for the finite
element analysis.
2. Creating geometries – the creation of both the workpiece and the dies.
3. Defining press object – worktable process parameters is created and defined.
4. Inserting geometries to the press – inserting all the created geometries to the desired
work press.
5. Defining material object – applying material to the workpiece.
6. Defining friction – creating friction object to the process.
7. Defining heat object – applying heat to both the dies and the workpiece during the
process.
8. Meshing – applying mesh element to the workpiece.
9. Defining axisymmetric simulation – performing simulation in the 2D axisymmetric by
defining the symmetrical plane of the process.
10. Defining forming control – controlling the forming process according to the desired
study case.
11. Running the simulation – to simulate the created process.
1. Creating the process

Creating process

Step 1: Creating the file

1. Click the New Project icon to create
the project.
2. Input the file name and save file
location and then click Okay.
3. In the window, select the Cold Forming
application.
4. Click Okay to confirm selection

Step 2: Defining the process

1. In process definition window,
choose Upsetting in the process
type.
2. Choose the 2D-axisymmetric for the
simulation type.
3. Choose Finite Elements (FE) for the
solver type.
4. Number of dies is to be set to 0.
5. Click Okay to confirm the selection.

Note: Once the process is created, the name

of the process can be renamed by right
clicking the process in the process tree.
2. Creating the geometries

Creating the dies

Step 1: Create dies using basic shape

1. In the Object catalog, and select
the Geometry option.
2. Select Basic shape function.
3. In the Basic shape window, input the
following value to create the first
die:
 Shape type: Cylinder
 Parameter: 40mm (radius),
10mm (height), 360o (angle),
circle value in radius
4. Make sure the resolution gradient
is set to Medium.
5. Click Okay to confirm selection.
6. Repeat the steps to create the second
die using the following values:
 Shape type: Rounded circle
 Parameters: 80mm (width),
80mm (depth), 20mm (height),
2mm (chamfer radius), round
depth.

Notes: Rename the first die as UPPERDIE

and the second die as LOWERDIE
Creating the workpiece

1. Repeat the same steps as in creating

the dies by opening the Basic shape
window.
2. In the Basic shape window, input the
following value to create the
workpiece:
 Shape type: Cylinder
 Parameter: 25mm (radius),
50mm (height), no chamfer
radius, 360o (angle), circle values
in radius
 Medium resolution gradient
3. Click Okay to confirm the selection.
3. Defining press object

Creating the press

Step 1: Create the press object

1. In the Object catalog, press and choose Press.
2. Select the Manual option.

Step 2: Defining the press object

1. In the Manual Press window, input the following value to create the press for this
case study:
 Press type: Hydraulic Press
 Hydraulic type: Constant velocity
 Velocity: 23 mm/s
2. Click Okay to confirm the selection.
4. Inserting geometries to the press

Insert geometries into the press

Step 1: Insert geometries

1. Press on the process in the
Process tree and then choose Insert.
2. Under the Dies option, click on
from existing geometries option.
This will open the insert geometries
window.
3. Insert both dies to the press, and the
UPPERDIE to be attached to the
25mm/s press and none for the
LOWERDIE.
4. Click Okay to confirm the selection.

Step 2: Defining the position of the dies

1.
5. Defining material object

Creating material object

Step 1: Using Library function
1. In the Object catalog, click and
C
select Material. C
2. Click on Library.
3. In the Material library, on the
General Steel tab.
4. Select material 15MnCr5_u.
5. Click Okay to confirm the selection.
6. Apply the material by clicking and
dragging it into the workpiece under
the Process tree.
C
6. Defining friction object

Defining friction
Step 1: Creating friction
1. In Object catalog, and select
Friction.
C
2. Click on Library.
3. In Friction library, select on bulk >
cold. C
4. Select on steel-cold-medium and
import it to the simulation.
5. Drag and drop the DB.steel-cold-
medium into UpperDie and
LowerDie.
7. Defining heat object

Defining heat object

Step 1: Creating heat object for die
1. In Object catalog, click and select
Heat > Die > Manual. C C C
2. In the Die Temperature window,
input the following parameters:
 Initial die temp.: 20oC
 Heat transfer coeff. to
environment: 50 Watt/(m2K)
 Heat transfer coeff. to C
workpiece: Automatic
 Emissivity for heat radiation to
environment: Automatic
3. Click Okay to confirm the selection.

Note: Drag and drop the die heat object into

the process UpsettingFE2D
C

Step 2: Creating heat object for workpiece

1. In Object catalog, click and select
Heat > Workpiece > Manual.
C
2. In the Workpiece Temperature C C

window, input the following

parameters:
 Workpiece Temperature – Initial
or Reheated: 20oC
 Heat transfer coeff. to
environment: 50 Watt/m2K
  Emissivity for heat radiation to
environment: Automatic
C
3. Click Okay to confirm the selection.

Note: After creating the heat object, drag

and drop the object into the workpiece

8. Meshing

Create meshing to workpiece

Step 1: Meshing the workpiece
1. To mesh the workpiece, simply

double click on Mesh under the

C
Process tree.
2. Set the element size to 1mm
3. Click on Create initial mesh.
4. Click OK and answer the question
with Yes.

C
 9. Defining axisymmetric simulation

Defining axisymmetric simulation

Step 1: Define axisymmetric plane
1. In Process tree, double click on
.
2. In the Axisymmetric Properties C

window, make sure the plane is in

(0,0) coordinate and the angle set to
90o.

3. Click on the to preview the

symmetrical plane in 2D.
C
4. Click on Close and then OK to
C
confirm the creation.
10. Defining forming control

Define forming control

Step 1: Forming control
1. In the Process tree, double click on Forming control to open the window.
2. In the Forming control window, select the Stroke tab. Note that the UpperDie is the
moving die, and the position is in the bottom dead center so there is no need to
define a stroke.
3. In Sub-stages tab, activate the following:

Note: The stroke for moving die is not required as the die is imported at the bottom dead
center. The difference between the die and workpiece will be calculated and automatically
assigned. DO NOT FORGET to activate ‘Position dies attached to the press’.
11. Running the simulation
After all the parameters of the simulation is completed, locate the Run button at
the control toolbar (bottom of the model window).