Defining Material Properties for Simulation The simulation of plain strain forging using ANSYS focuses on static structural simulations, assuming no vibrations during load application. The materials used are copper and die steel, with specific properties defined: Young's modulus for copper is 110 GPa and yield strength is 33 MPa; die steel primarily deforms elastically with a Young's modulus of 210 GPa. Both materials' behaviors under stress are characterized by isotropic elasticity.
Creating Geometry for Analysis Geometry creation begins in the XY plane where a rectangle representing the workpiece is drawn to specified dimensions (0.05m width x 0.1m height). Two additional sketches create upper and lower dies while ensuring they remain distinct bodies through 'add frozen' operations to prevent merging in ANSYS modeling software.
Establishing Connections & Mesh Settings Symmetry lines are established along vertical edges, defining bonded contacts between the dies and copper block while accounting for friction coefficients at contact regions set at 0.05 due to its significance in forging processes. A large deflection setting accommodates anticipated deformation up to 25%. Meshing follows best practices by aligning mesh lines across contacting elements as quadratic elements enhance accuracy.
Executing Pressure Application & Analyzing Results Applying an external pressure of approximately -86 MPa simulates real-world conditions leading to expected directional deformation results around maximum compressive strains near top die areas observed post-simulation run-throughs within acceptable error margins compared against theoretical predictions—demonstrating effective analysis outcomes including equivalent stresses throughout components involved.