Narendra Singh

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Everything posted by Narendra Singh

  1. Narendra Singh

    How to use existing mesh in Click2Extrude Metal

    Steps: Setup model as in tutorial #1 in training manual Export Parasolid file from Click2Extrude. We will generate mesh using this CAD This makes sure that CAD in C2E is same we are going to use for meshing Mesh the model manually and export as GRF/FEM/BDF Now come back to C2E & Load the Parasolid. Make sure the Geometry components & meshed components match Verify the unit set in C2E is same the incoming mesh In C2E, go to the export panel and select Mesh type as Existing and pick the exported GRF file from step #3.
  2. Narendra Singh

    How To Simulate Dead Cycle Time?

    Overview Need: Understand heat transfer characteristics during billet loading and upsetting stages Feature: Perform thermal analysis during dead cycle time Compute heat transfer between billet and container/liner Calculates billet temperature at the start of extrusion Benefit: Help design better container heating system to maintain optimum billet temperature Minimize dead cycle time Increase productivity What is Dead Cycle Time? The time between the end of one extrusion cycle and the start of the next cycle Dead cycle time is typically between 15 sec to 20 sec First half is spent in removing the back end of the previous billet Remaining time is for loading and upsetting the new billet During upsetting process, the bottom half of the billet loses heat to the container Creates temperature gradient in the lateral direction Material flows faster in the top half compared to the bottom half Will produce non-uniform flow at the die exit The important factor to consider while designing container heating system Refer to attached document on how to use this feature: Click2Extrude Metal - How To Simulate Dead Cycle Time.pdf
  3. Narendra Singh

    How to reduce CPU time and get quick solution

    Geometry cleanup: Merge fixed points that do not significantly alter the geometry (such as very small fillets).This will increase the solver speed. For the same number of equations, the solver spends more time factoring matrices from elements with bad angles. Adjust element size: There are three meshing option fine, Medium, and Coarse. Coarse mesh will run faster. Increase the nonlinear tolerance to 0.01: This will reduce the times solver is called. This can reduce CPU time by 50%. Use this option, If model has more than 4 M elements or 0.5 M Nodes Running Bearing optimization Running Transient simulation
  4. Click2Extrude Metal supports two level of licenses: Standard Advanced Standard Version supports following features: Profile nose cone analysis Seam weld strength prediction Tool deflection analysis Coupled tool deflection analysis with OptiStruct Advanced Version supports following features: All features that are available the standard version Charge weld analysis Backend defects analysis (skin tracking) Automatic ram speed correction based on press tonnage Thermal management & fully coupled analysis* User-defined functions for material data, etc.* Advanced license supports all existing features in the solver, however, some of the advanced features do not have a user interface (for example, last two items in the above list).
  5. Yes. Click2Extrude simulate the material flow inside die cavity and then applies contact forces on to tool surfaces to accurately predict tool deformation and stresses.
  6. Yes. It is possible to add new material. Click2Extrude also allows a user to define material using new constitutive model using User Defined Material as DLL.
  7. Click2Extrude supports direct and indirect extrusion presses.
  8. Click2Extrude helps in predicting extruded profile nosecone, extrusion tool deformation and stresses, predict charge weld length and back end scrap, predict seam weld locations and strength. It also helps in optimizing bearing lengths and ram speed.
  9. Automatic bearing length optimization, predicting die deflection, dummy block failure, container liner expansion, die wear and excessive heating, improper thermal management.
  10. Click2Extrude help in predicting charge weld length, seam weld, billet skin detects uneven grain size distribution.
  11. Visible defects like extruded profile deformation, uneven wall thickness, die pickup lines (streak lines)
  12. Yes. Balancing the die by fine tuning the bearing lengths manually and iteratively in production can be time consuming and expensive. Click2Extrude Metal automatically optimizes the die with leading numerical methods in a single set up.
  13. No. Click2Extrude offers just one package with access to all features.
  14. Narendra Singh

    Which languages does Click2Extrude support?

    English, Italian, Spanish, Portuguese, French, German, Chinese, Japanese, Korean and Turkish
  15. Narendra Singh

    Which platforms does Click2Extrude run on?

    Interface support Windows 64 bit. The solver supports both - Windows and Linux If the user is involved with many large and complex dies, then Click2Extrude also has the ability to perform simulations on a big Linux machine. In this scenario, the user will work on light configuration windows desktop which is used for model setup then Click2Extrude launches simulations on large Linux cluster seamlessly.
  16. To perform extrusion analysis, user will need followings, 3D CAD of extrusion die Processing parameters Polymer melt properties Polymer melt inlet temeprature Polymer melt inlet speed/flow rate Die temeprature
  17. To perform extrusion analysis, user will need followings, 3D CAD of extrusion die Processing parameters Alloy name used for extrusion Billet dimension: Billet diameter and length Container inner diameter Ram speed Billet Preheat Container temperature Die temperature
  18. Narendra Singh

    What CAD files are supported by Click2Extrude?

    Click2Extrude supports all major CAD file types. Some of them are listed below, CATIA IGES Inventor Parasolid Pro/Engineer SolidWorks STEP (.step, .stp) STL (ASCII .stl): UG NX (Unigraphics)
  19. Narendra Singh

    how to calculate the shear stress in click2extrude

    Performing stress analysis on die tooling is possible using Click2Extrude. Click2Extrude export forces from polymer during extrusion process on the tool and perform accurate tool deflection and stress analysis. Since you mentioned blow film, as long as you focus on flow inside die cavity - it is possible to perform this simulation. Narendra Singh
  20. Narendra Singh

    blown film application

    Thank you. Click2Extrude can simulation how polymer melt is flowing through die cavity. Blowing process happens outside die and we do not simulate that. We will consider this in our development plan. Thank you, Narendra Singh
  21. Narendra Singh

    Click2Extrude ERRORS

    1. Can you please confirm if you have tried all training models? 2. Can you please confirm which version you are using? Latest version is 2018. Your model is working with 2018. I have not tried in older version.
  22. Narendra Singh

    EW Batch error

    Dear Miezan, Have you tried training models? When you are learning Click2Extrude, it is strongly recommended to first try tutorial models. These are available in Help document. Press F1 key on key board. I checked your model, the solids organized not as per requirements. 1. Polymer die assemblies are made of stack/series of steel plates. They are placed one after another. 2. Hence, our workflow is geared towards this assumption, you should have series of die plates - placed one after another. 3. when you extract flow volume, Click2Extrude will automatically extract solids from each die plate and name them as Plate1, Plate2, .. and the last plate is assembly where polymer takes final shape is called as Land plate; hence last solid is named as "Land" 4. then you go and extract profile solid Issues in your model: You have entire bar and nozzle named as Land. But it should have been sub dived as shown in image below. I have corrected the model and please try with that. nozzle_corrected.stmod
  23. Narendra Singh

    EW Batch failed

    Dear Milanb, Can you please provide more details on what trouble you are facing? Have you tried tutorial models? I will recommend to first try tutorial models and understand requirement for Click2Extrude. Regards, Narendra Singh
  24. Narendra Singh

    Extrusion die

    Extrusion die for aluminum pipe.
  25. Narendra Singh

    Handle Symmetric Model

    Import die geometry and setup model as per in Tutorial #1 in this training manual After complete setup, Trim full model for desired sector. Delete unwanted solids and bearing curves. Reorganize solids as Billet, Feeder, Portholes, Pocket1 etc. as it was modeled. Also organize lines belonging to bearing curve as BearingCurve What is angle of symmetric model for simulation? 180° (Need extra step to setup) 90° 45° 30° 10° And more Note: Other then 180° sector model, there is no special settings required to simulate sector of full model. Requirement for 180 ° Sector Model? What we need? For 180° sector model, we need at least one edge/imprint on billet solid crossing billet center. Why we need? To detect half symmetry, internal BC capture module needs a nodes at center (X=0,Y=0) of Billet_DummyBlock face. This center node will only be created when there is edge/imprint on billet solid E.g. In figure below, there is no node near X=0,Y=0. this is because there is not edge/imprint at billet center. When there is a edge near billet center then batch mesher automatically creates a node at billet center. How to Add a Edge/Imprint on Billet? Quick steps These steps should be followed once model is ready to solve Trim billet solid at billet center Combine two half's of billet solid Remove all imprints lines on billet solid except the one on billet symmetric face Organize billet solid as Billet again Details are in attached PDF file - How to - Handle Symmetric Model in C2E.pdf