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:
(Figure 2)
-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
(Figure 3)
-the contact properties
(Figure 4)
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
Ensure your mesh is sufficiently refined in high-strain regions and consider using adaptive meshing (ALE) with appropriate frequency settings or switching to an explicit dynamic solver for severe deformations. This will solve your problem.
Engr. Tufail Thank you for your feedback. I am already using the explicit dynamic solver and have also activated ALE. My previous settings here were Frequency 5 and remeshing sweep per inc. 3. What settings would you recommend for ALE? and should I refine the mesh of the strand even further?
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