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ASSIGNMENT 2: COPRESS ON TEST-EFFECT OF FR CT ON

Student name: Birgl Ra ito lu Date: 20.05.2009

To investigate the effect of friction on deformation behavior of an elasto-plastic material during compression test is the aim of this report. Compression test is used to analyze the metal forming processes such as forging, drawing and extrusion that work with high load. In this report barreling simulation is investigated since the elasto -plastic material is used. Since the length of material is not so long the buckling which is a serious problem in aerospace and automotive structure is not observed. B arreling occurs due to friction. When the specimen is compressed it contacts the face of pusher and some frictions are applied by those apertures. Due to the friction material can not move therefore bulge part occurs at the two edge of specimen. Also dead metal zone region occurs which limits the deformation. Bulge and dead metal zone parts are seen in the figure 1 together.

1- MODEL DESCRIPTION
This model simulates the affect of friction on deformation behavior of an elastoplastic materia during compression test. An axsymmetric model is developed, symmetry axis is x as seen figure 5. Each simulation programs have different symmetry axis. For example SYSWELD uses y-axes but MSC MARC uses x-axis. Using symmetry half of the billet is modeled.

Figure 5:Id bacfaces Cylindirical bilet having 6.5 mm length and 10 mm diameter is modelled.Simple sketch of bilet is shown in the figure 6.

Figure 6: Simple sketch of specimen

Figure 7: Sketch of contact bodies In MARC environment under Contact button contact bodies are defined. Four contact bodies should be defined for this simulation name as deformable, base, pusher and symmetry axis as seen figure 7 systematically. Deformable body which is seen in pink color in figure 8 is modeled at first and th en base which is a rigid body and zero velocity controlled body is defined. Base is in orange color in figure 8.Third defined body is pusher and it is a rigid body too but it is load controlled and it is seen in yellow color in below figure. Symmetry axis is in green color in figure 8 and it is defined in the bottom line which is different from figure 7. Bottom line is used to define symmetry because MARC uses x-axis as a symmetry axis. The point in red circle is an extra node that we input as fixed displa cement in y-displacement and it is defined as a point load.

Figure 8: ID Contacts The material properties of modeled elasto-plastic rigid body are given as follows: Young s Modulus is 210000 MPa ,poisson s ratio is 0.31.Flow curve and corresponding gra ph is below. Table 1: TEPS and stresses Total equivalent plastic strain 0 1 6 True stress 410 420 425

Figure 9: Flow curve U and V domain are taken from -1 to 8 in Mesh Generation. Spacing is 0.5 . Under subdivide button divisions are taken as 10x10x1 and nothing is input as bias factor. An axisymetric element type is modelled.
In this model compression test with a hydrolic testing machine is simulated. In hydrollic machine load is increasing with time as seen in figure 10.I n this case load is increase from zaro to 45000.Total load case time is 13 seconds. The number of steps are taken as 50.

Figure10: Loading curve

2- ANALYSIS RESULTS
2.1- Deformed Shape 2.1.a ) Frictionless deformation Deformed shapes after compressive load magnitude of 45000MPa is applied in 13 seconds are seen below figures. In the case of zero friction ( Figure11 & 12) barreling (bulging effect) is not seen because the friction is the reason of the barreling as I explained at before. Only elongation is observed in this case. The magnitude of displacement in X displacement is 1.817 mm as shown in red circle in the figure. Since there is no friction betwee n contact bodies dead metal zone is not observed. Also the magnitude of displacement in Y displacement is 8.882 mm.

Figure 11: Contour bands of displacement x (when =0 )

Figure 12: Contour bands of displacement y (when =0 ) 2.1.b ) When the friction coefficient is 0.25 Deformed shapes after compressive load magnitude of 45000MPa is applied in 13 seconds are seen below figures. In the case of 0.25 friction ( Figure 13 & 14) barreling (bulging effect) is seen because the friction is the reason of the barreling as I explained at before. In this case dead metal zone is observed due to bulging effect. The magnitude of displacement in X displacement is 1.408 mm as shown in red circle in the figure.Also the magnitude of displacemen t in Y displacement is 6.947 mm. The dead metal zone is seen in Displecemnet Y in blue color in the Figure 14.

Figure 13: Contour bands of displacement X(when =0.25 )

Figure 14 : Contour bands of displacement y(when =0.25 ) 2.1.c) When the friction coefficient is 0.70 Deformed shapes after compressive load magnitude of 45000MPa is applied in 13 seconds are seen Figure 15 & 16, barreling (bulging effect) is seen due to 0.7 friction .In this case dead metal zone is observed due to bulging effect. The dead metal zone is seen in Displacement Y in blue color in the Figure 16. The magnitude of displacement in X displacement is 1.089mm as shown in red circle in the figure. Also the magnitude of displacement in Y displacement is 5.631 mm.

Figure 15: Contour bands of displacement X(when =0.70 )

Figure 16 : Contour bands of displacement y(when =0.70 )

When the displacements are compared in the different friction coefficients Table 2 is obtained. Table 2:Displacements and friction coefficients Displacement X -1.817 -1.408 -1.089 Displacement Y 8.882 6.947 5.631

With zero friction With 0.25 friction With 0.70 friction

When friction coefficient increases the displacement decreases as shown above table. Since there is contraction in x axis mines sign is used before displacement X values. Also when the friction coefficient increases dead metal zone region which limits the deformation should increases. This situation is seen well in Figure 14 and 16he area of blue region (dead metal zone region) is higher in Figure 16

that has higher friction coefficient (0.7)than Figure 14 which has less friction coefficient(0.25).

2.2.1- Strain Calculations

 for x direction
Engineering strain e = (L / L o where Lo=6.5mm

True strain

It = ln (1+e)

In case of zero friction we have -1.817 mm displacement in x displacement. The initial length of specimen is 6.5 mm. So e=(-1.817/6.5)=-0.279. True strain is calculated using engineering strain as fallows; Itx =ln(1-0.279)=-0.327. Other calculated values are tabulated in Table 3.
 For y direction

Engineering strain True strain

e = (d / d o
It = ln (1+e)

where do=10mm

Table 3: The change of strains due to different friction coefficients friction 0 0.25 0.70 Disp. x -1.817 -1.408 -1.089 Disp. y 8.882 6.947 5.631 ex -0.279 -0.217 -0.167 ey 0.8882 0.6947 0.5631
Itx -0.327 -0.245 -0.183 Ity 0.636 0.528 0.447

2.2.2- Plot of the Strains

According to Table 3 data below graph is drawn. It is seen clearly that when the friction coefficient increases which means deformation increases (also dead metal zone region decrease) the strain decreases in y and x direction. But since we put mines sign in front of engineering strains in x direction, ey and Itx are seen in
increasing manner with increasing friction coefficient in Figure 18.

Figure 17: the change of strains according to different friction coefficient values

2.2.3- Comparison and Comments The below part of Figure 17 is expected reason. The values of true strain and engineering strain are very close. But in above part of Figure 17 the curves are a little far away from each other. The displacement in y direction may be calculated wrongly with MSC MARC, so strain values are different as here. To take correct values number of steps should increased in below Loadcase /Mechanical/Static button .

3- REFERENCES
[3]Lab Lecture Notes METE 304

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