3D_Lab11_GearCarrier

http://www.cadfamily.com/a/CAE_FEA_CFD/Forge-CAST/3D-Lab11-GearCarrier_4074.html

This is a two step forging operation with a relatively long dwell between the furnace and
the press. The first operation is straightforward and is not likely to cause difficulties.
The second operation is more complex and the results are much more difficult to predict,
which makes simulation useful. There are three possible approaches to simulating this
process:
Simulate the entire process in 3D, including heat transfer, upset, and finish. This is
straightforward to run, and accurately captures temperature and strain distributions in the
workpiece.
Simulate the upset in 2D, transfer the data to 3D, and simulate the extrude in 3D.
The 2D operation is easier to set up and runs very quickly. Translation to 3D requires the
use of 2D to 3D conversion utility, which is available with DEFORM™. Like the entire
3D simulation, this approach accurately captures temperature and strain distributions in
the workpiece.
Create the upset part geometry in a CAD model, and simulate only the second
operation. This method is quick, and requires less effort than running the full
simulation, but temperature and strain distributions will not be correct, and the
discrepancies will affect load calculations, and in some cases may affect material flow
behavior.
For this problem, we will run the entire simulation in 3D.