Assistance with FEM Simulation of Continuous Rotary Extrusion in Abaqus

[Nilsc15]

Hello everyone,

I am currently working on my master's thesis on the FEM simulation of the continuous rotary extrusion process and using the FEM software Abaqus for this purpose.

Model Description:
Figure 1 shows the setup of my model. In the continuous rotary extrusion process, the billet (red) is driven by the friction and rotation of the rotating wheel (yellow) and pressed through a die in the tooling assembly (green).


Problems in the Simulation:
During my simulation, I repeatedly encounter the following issues:

1. Excessivly distorted elements
2. The billet moves past the counterholder
3. Warning message about overlaps between the billet and the tooling assembly

-the error "Excessively Distorted Elements" causes the simulation to terminate.

The attached figures show my current settings for contact conditions, step parameters, material data, and boundary conditions. Additionally, I have activated ALE.

-material data for the billet


-the contact properties

1. Contact conditions between the billet and the counterholder as well as the die 2. Between the groove of the rotating wheel and the billet 3. Between the tooling assembly and the billet // all with hard contact for normal behavior

I used general Contact with individual property assignments.

The rotating wheel rotates at 1r/time and is initially accelerated linearly

Has anyone experienced similar issues and can provide some guidance?
I would appreciate any help!

Thank you in advance.

Best regards

 

[SWComposites]

suggest you delete this post and repost in the Abaqus forum.