3d simulator: extrusion simulation software
TRANSCRIPT
MTD SA, Route de Muraz 16, CH 3960 Sierre, Switzerland
[email protected] / www.m-td.com
EXTRUSION SIMULATION SOFTWARE
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
3D Simulator is simulation software developed by extrusion experts for dies makers and extruders.
3DS enables the user to perform fast three-dimensional simulations of the extrusion process enabling one to compute stress and deformation, temperature and fluid flow.
Costly and time-consuming die trials on presses can be replaced by virtual prototyping and testing with computers. Numerical trials allow selecting optimal CAD concepts. This leads to savings on correction costs and longer lifetime of critical parts.
Efficient computer simulations with optimized algorithms enable the user to visualize and understand extrusion material flow, temperature, pressure, mechanical and thermal loads, as well as to design robust die sets by accurately predicting deflections and stresses due to these loads. It enables the user to minimize the die design to prototyping time and reduce the associated costs and overall product development cycle time.
INTRODUCTION
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
BENEFITS FOR DIES MAKERS
INTEGRATION OF SIMULATION INTO DIE DESIGN PROCESSThe optimized algorithms reduce strictly the calculation time allowing including simulation into “industrial” die design process.The parallel computing option introduced in the new version uses as well the performance of actual multi-core processors, reducing calculation time to few minutes
It enables the designer to control it design, applying modifications and test again the optimized design, or to test different designs in reasonable time.
No prior knowledge of numerical simulation or methods is needed to perform simulations of complex cases. Automatization and user friendly interface enables designers to use immediately the software.
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
BENEFITS FOR DIES MAKERS
DIES DESIGN OPTIMIZATION
3DS helps designer to:• Define the die shape to optimize the flow balance• Define bearing length• Define the pocket (sink-in)• Predict the quality of seams weld in welding chambers• Predict the profile shape• Minimize the tool deflection, mandrels shift, to meet the product
tolerances.
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESBASED ON 3D MODEL OF DIFFERENT DIES TYPES
• Solid, semi hollow and hollow dies• Multi-holes dies• Feeders, plates and spreaders
Design your die in 3DOn your CAD softwareor retreive existing 3D model
Create aluminum by subtraction
Create die part by merging dies components, ring and bolster
Export in STEP
Export in STEP
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESSEVERAL OPTIONS OF SIMULATION PROCESS
• Only with alloy for flow balance, bearings, pocket optimization and quality of seams weld in welding chambers prediction
• With alloy and die for profile shape prediction, die stresses and deformation
• Constant bearing calculation mode to validate quickly a die design and define bearings lengths (coupled with ABC software)
• Real bearing calculation mode to validate bearing defined by designer and quality of seams weld in welding chambers(calculation mode used also for profile with large difference thickness)
• Standard and parallel computing
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Flow speed of alloy material
Check flow into feeding holes
Check if flow is well balanced between
feeding holes
Visualize flow speed on exit
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Pressure of alloy material
Control global pressure to validate press capacity
Check pressure in welding chambers to predict the quality of seams weld
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Temperature of alloy material
Control global temperature
Check temperature on exit to identify profile surface quality
problems
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Temperature of die
Control global temperature
Check temperature around bearings identify profile surface quality
problems
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Die’s stresses
Analyze stresses into die to identify fragile parts and risk of breakages
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Displacement : die’s deformations
Check mandrels displacements Check the efficiency of the bolster
Predict tongue deflection
Displacements can be calculated considering mechanical and thermal effectsor only mechanical effect
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
CAPABILITIES & MAIN FEATURESCALCULATION TYPES
Displacement : predict profile shape
Control X/Y displacements to define modifications to apply on the profile
Visualize the profile shape deformation
deformation
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDUREOVERVIEW
Simulation process is realized in few stepsProcess is partially automatized to let the designer control the processAutomatization can be done on demand
PROCESS CHARTCAD preparation Simulation type
selection
Define modifications and restart the process if necessary
Simulation calculation
Data processing analysisSimulation data preparation
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / PROCESS CHARTSTEP 1 : CAD PREPARATION
Design your die project in 3DCreate alloy and/or die stackExport them as STEP filesUse only alloy to control flow balance problems or to optimize process parametersUse alloy and die for a complete analysis
CAD model
Alloy part defined by subtractionIncluding billet length
Die step model is defined including :• Dies parts• Ring • Bolster
Necessary to consider real conditions for temperature, stresses and deformation analysis
STEP model for simulation
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / PROCESS CHARTSTEP 2 : simulation type selection
Define the simulation type:• Nb of processing units 1 or more for standard or parallel
computing
• Simulation type :Calculation type1 for dies designer: to make a fast simulation (recommended for first analysis or flow balance optimization)3 for dies designer: to validate bearing defined by designer or if profile has large thickness difference, for extruders: to analyze die or production defect on existing die
Model used1 (alloy only) for first analysis or if you are confident in die deformations0 (alloy + die) for final analysis or if you need to control die stresses and deformation
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / PROCESS CHARTSTEP 2 : simulation data preparation
Define geometrical data:• Enter alloy type• Import 3D models• Enter geometrical data
Define mesh models:• For simple calculation prepare only alloy mesh model• For complete calculation prepare alloy and die mesh model
Mesh generation is made automatically
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / PROCESS CHARTSTEP 3 : simulation calculation
Start calculations• Flow to check flow balance and pressure
• Alloy + die + Temperature to check temperature into alloy and prepare thermo-mechanical of die(if you make only alloy simulation, only temperature alloy will be calculated)
• Structure + temperature to calculate dies stresses • Displacement to check dies displacements
Prepare data for analysis• As described into solvers windows, it’s necessary to post-
process data after each step to generate data for the next simulation
• Prepare data for each step as defined into the windows
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / PROCESS CHARTSTEP 4 : simulation results analysis
First, analyze alloy results• Check flow balance, bearings speed in first• Control pressure
→ Dies designer: define modifications to apply on die project and run another calculation if necessary
• Check alloy temperature (optional)
Second, analyze die results• Check die stress• Analyze die deflection to apply modification on profile shape
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / BEST PRACTICEPROCESS CHART FOR A BEST PROJECT
Work on alloySimulate and
analyze AL flow(and pressure)
Apply modification on
die project
Go back to the start
Prepare die model
Flow balance ok
Simulate and analyze temperature
Die stress and displacement
Apply modification on die project
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / BEST PRACTICEPROCESS CHART FOR QUALITY IMPROVEMENT
Prepare alloy and die models
Simulate and analyze AL flow(and pressure)
Simulate and analyze
temperature
Simulate and analyze die stress and deflection
Define modifications and apply them on
3D model
Make a new process to validate modifications
Control flow balance and
bearing length
Control quality surface
Control cause of breakages
Profile shape tolerancesImbalance flow due to die
deformation
Ok
Realize modifications on physical
die
Test on press
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
PROCEDURE / BEST PRACTICEPROCESS CHART FOR EXTRUSION PROCESS OPTIMIZATION
Work on alloyDefine
parameter set
Simulate and analyze AL flow
and pressure
Simulate and analyze
temperature
modify parameter set
Control profile speedControl pressure
Control profile temperature
Ok
Apply parameter
set on press
MTD SA, Route de Muraz 16, CH 3960 Sierre,Switzerland [email protected] / www.m-td.com
OTHER MTD’S SERVICES
3D CAD DESIGNIf you don’t design in 3D dies, we can do it for you from 2D drawings.
SIMULATIONWe offer also the possibility to realize the complete analysis in a short time from your 2D drawings and the necessary data.We offer different level of services:• Simple calculation• Simulation and analysis of design• Simulation and modifications (delivery of 3D model ready to
manufacture)