{"id":5433,"date":"2026-04-21T20:26:19","date_gmt":"2026-04-22T02:26:19","guid":{"rendered":"https:\/\/kimeca.com.mx\/?p=5433"},"modified":"2026-04-21T20:26:24","modified_gmt":"2026-04-22T02:26:24","slug":"forging-with-multiple-complex-dies","status":"publish","type":"post","link":"https:\/\/kimeca.com.mx\/index.php\/forging-with-multiple-complex-dies\/","title":{"rendered":"Forging With Multiple Complex Dies"},"content":{"rendered":"<p>[et_pb_section fb_built=&#8221;1&#8243; fullwidth=&#8221;on&#8221; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_fullwidth_code _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; custom_margin=&#8221;|||50px|false|false&#8221; global_colors_info=&#8221;{}&#8221;]<nav aria-label=\"breadcrumbs\" class=\"rank-math-breadcrumb\"><p><span class=\"last\">Home<\/span><\/p><\/nav>[\/et_pb_fullwidth_code][\/et_pb_section][et_pb_section fb_built=&#8221;1&#8243; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_row _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_column type=&#8221;4_4&#8243; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_text _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;]<\/p>\n<h2 class=\"title topictitle2 title\" data-fs=\"20\"><span class=\"ez-toc-section\" id=\"Problem_Description\"><\/span>Problem Description<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p><a href=\"https:\/\/kimeca.com.mx\/index.php\/products\/dassault-systemes\/simulia\/abaqus-explicit\"><strong>Product: Abaqus\/Explicit<\/strong><\/a><\/p>\n<p data-fs=\"14\">The benchmark problem is an axisymmetric\u00a0<a href=\"https:\/\/www.youtube.com\/watch?v=fxMQvi4-TlQ\" rel=\"noopener\"><span class=\"highlight\">forging<\/span><\/a>, but in this example, both axisymmetric and three-dimensional geometric models are considered. For the axisymmetric models, the default hourglass formulation (<span class=\"ph ph abqparameter\" data-fs=\"14\">HOURGLASS<\/span>=<span class=\"ph ph abqparamvalue\" data-fs=\"14\">RELAX STIFFNESS<\/span>) and the enhanced strain hourglass formulation (<span class=\"ph ph abqparameter\" data-fs=\"14\">HOURGLASS<\/span>=<span class=\"ph ph abqparamvalue\" data-fs=\"14\">ENHANCED<\/span>) are considered. For the three-dimensional geometric models, the pure stiffness hourglass formulation (<span class=\"ph ph abqparameter\" data-fs=\"14\">HOURGLASS<\/span>=<span class=\"ph ph abqparamvalue\" data-fs=\"14\">STIFFNESS<\/span>) and the enhanced strain hourglass formulation with the orthogonal kinematic formulation (<span class=\"ph ph abqparameter\" data-fs=\"14\">KINEMATIC SPLIT<\/span>=<span class=\"ph ph abqparamvalue\" data-fs=\"14\">ORTHOGONAL<\/span>) are considered. Each model is shown in\u00a0Figure 1. Both models consist of two rigid dies and a deformable blank. The blank&#8217;s maximum radial dimension is 895.2 mm, and its thickness is 211.4 mm. The outer edge of the blank is rounded to facilitate the flow of material through the dies. The blank is modeled as a von Mises elastic-plastic material with a Young&#8217;s modulus of 200 GPa, an initial yield stress of 360 MPa, and a constant hardening slope of 30 MPa. The Poisson&#8217;s ratio is 0.3; the density is 7340 kg\/m<sup class=\"ph sup ph sup\" data-fs=\"9.33333\">3<\/sup>.<\/p>\n<p data-fs=\"14\"><img decoding=\"async\" class=\"aligncenter wp-image-5440 size-medium\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure1AxisymetricAndThree-DimensionalModelGeometries-269x300.webp\" alt=\"Figure1 Axisymetric And Three-Dimensional Model Geometries\" width=\"269\" height=\"300\" title=\"\" srcset=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure1AxisymetricAndThree-DimensionalModelGeometries-269x300.webp 269w, https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure1AxisymetricAndThree-DimensionalModelGeometries.webp 436w\" sizes=\"(max-width: 269px) 100vw, 269px\" \/><\/p>\n<p style=\"text-align: center;\" data-fs=\"14\"><strong>Figure 1. Axisymmetric and three-dimensional model geometries.<\/strong><\/p>\n<p data-fs=\"14\">Both dies are fully constrained, except for the top die, which is moved downward by 183.4 mm at a constant velocity of 166.65 mm\/s.<\/p>\n<p data-fs=\"14\">\n<h3 data-fs=\"14\"><span class=\"ez-toc-section\" id=\"Case_1_Axisymmetric_model\"><\/span>Case 1: Axisymmetric model<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>The blank is meshed with CAX4R elements. A fine discretization is required in the radial direction because of the geometric complexity of the dies and the large amount of material flow that occurs in that direction. Symmetry boundary conditions are prescribed at r=0. The dies are modeled as TYPE=SEGMENTS analytical rigid surfaces. The initial configuration is shown in Figure 2.<\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-5441 size-medium\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure2InitialConfigurationForAxisymmetricModel-300x191.webp\" alt=\"Figure 2. Initial configuration for the axisymmetric model.\" width=\"300\" height=\"191\" title=\"\" srcset=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure2InitialConfigurationForAxisymmetricModel-300x191.webp 300w, https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure2InitialConfigurationForAxisymmetricModel.webp 330w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 2. Initial configuration for the axisymmetric model.<\/strong><\/p>\n<h3><span class=\"ez-toc-section\" id=\"Case_2_Three-dimensional_model\"><\/span>Case 2: Three-dimensional model<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>The blank is meshed with C3D8R elements. A 90\u00b0 wedge of the blank is analyzed. The level of mesh refinement is the same as that used in the axisymmetric model. Symmetry boundary conditions are applied at the x=0 and z=0 planes. The dies are modeled as TYPE=REVOLUTION analytical rigid surfaces. The initial configuration of the blank only is shown in Figure 3. Although the tools are not shown in the figure, they are originally in contact with the blank.<\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-5442 size-medium\" title=\"Figure 3. Initial configuration mesh for the three-dimensional model.\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure3InitialConfigurationMeshForThree-DimensionalModel-300x169.webp\" alt=\"Figure 3. Initial configuration mesh for the three-dimensional model.\" width=\"300\" height=\"169\" srcset=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure3InitialConfigurationMeshForThree-DimensionalModel-300x169.webp 300w, https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure3InitialConfigurationMeshForThree-DimensionalModel.webp 337w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 3. Initial configuration mesh for the three-dimensional model.<\/strong><\/p>\n<h2><span class=\"ez-toc-section\" id=\"Adaptive_meshing\"><\/span>Adaptive meshing<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p>A single adaptive mesh domain that incorporates the entire blank is used for each model. Symmetry planes are defined as Lagrangian boundary regions (the default), and contact surfaces are defined as sliding boundary regions (the default). Since this problem is quasi-static with relatively small amounts of deformation per increment, the defaults for frequency, mesh sweeps, and other adaptive mesh parameters and controls are sufficient.<\/p>\n<h2><span class=\"ez-toc-section\" id=\"Results_and_discussion\"><\/span>Results and discussion<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p>Figure 4 and Figure 5 show the deformed mesh for the axisymmetric case using the default hourglass control formulation (HOURGLASS=RELAX STIFFNESS) at an intermediate stage (t=0.209 s) and in the final configuration (t=0.35 s), respectively. The elements remain well shaped throughout the entire simulation, except the elements at the extreme radius of the blank, which become very coarse as material flows radially during the last 5% of the top die&#8217;s travel. Figure 6 shows contours of equivalent plastic strain after forming.<\/p>\n<p>Figure 7 and Figure 8 show the deformed mesh for the three-dimensional case using the pure stiffness hourglass control (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at t=0.209 and t=0.35, respectively. Although the axisymmetric and three-dimensional mesh smoothing algorithms are not identical, the elements in the three-dimensional model also remain well shaped until the end of the analysis, when the same behavior that is seen in the two-dimensional model occurs. Contours of equivalent plastic strain for the three-dimensional model (not shown) are virtually identical to those shown in Figure 6.<\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-5443 size-medium\" title=\"Figure 4. The deformed mesh for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at an intermediate stage\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure4TheDeformedMeshForAxisymmetricModelUsingTheDefaultHourglassFormulation-Hourglass-RelaxStiffness-AtAnIntermediateStage-300x148.webp\" alt=\"Figure 4. The deformed mesh for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at an intermediate stage\" width=\"300\" height=\"148\" srcset=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure4TheDeformedMeshForAxisymmetricModelUsingTheDefaultHourglassFormulation-Hourglass-RelaxStiffness-AtAnIntermediateStage-300x148.webp 300w, https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure4TheDeformedMeshForAxisymmetricModelUsingTheDefaultHourglassFormulation-Hourglass-RelaxStiffness-AtAnIntermediateStage.webp 330w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 4. The deformed mesh for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at an intermediate stage.<\/strong><\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-5444 size-medium\" title=\"Figure 5. The deformed mesh for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at the end of forming.\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-5.-The-deformed-mesh-for-the-axisymmetric-model-using-the-default-hourglass-formulation-HOURGLASSRELAX-STIFFNESS-at-the-end-of-forming-300x142.webp\" alt=\"Figure 5. The deformed mesh for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at the end of forming.\" width=\"300\" height=\"142\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 5. The deformed mesh for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at the end of forming.<\/strong><\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-5446 size-medium\" title=\"Figure 6. Contours of equivalent plastic strain for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at the end of forming.\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-6.-Contours-of-equivalent-plastic-strain-for-the-axisymmetric-model-using-the-default-hourglass-formulation-HOURGLASSRELAX-STIFFNESS-at-the-end-of-forming-300x202.webp\" alt=\"Forging FEA Manufacturing Simulation\" width=\"300\" height=\"202\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 6. Contours of equivalent plastic strain for the axisymmetric model using the default hourglass formulation (HOURGLASS=RELAX STIFFNESS) at the end of forming.<\/strong><\/p>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-5447 size-medium\" title=\"Figure 7. The deformed mesh for the three-dimensional model using the pure stiffness hourglass formulation (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at an intermediate stage.\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-7.-The-deformed-mesh-for-the-three-dimensional-model-using-the-pure-stiffness-hourglass-formulation-300x162.webp\" alt=\"Figure 7. The deformed mesh for the three-dimensional model using the pure stiffness hourglass formulation (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at an intermediate stage.\" width=\"300\" height=\"162\" srcset=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-7.-The-deformed-mesh-for-the-three-dimensional-model-using-the-pure-stiffness-hourglass-formulation-300x162.webp 300w, https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-7.-The-deformed-mesh-for-the-three-dimensional-model-using-the-pure-stiffness-hourglass-formulation.webp 337w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 7. The deformed mesh for the three-dimensional model using the pure stiffness hourglass formulation (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at an intermediate stage.<\/strong><\/p>\n<p style=\"text-align: center;\"><img decoding=\"async\" class=\"aligncenter wp-image-5448 size-medium\" title=\"Figure 8. The deformed mesh for the three-dimensional model using the pure stiffness hourglass formulation (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at the end of forming.\" src=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-8.-The-deformed-mesh-for-the-three-dimensional-model-using-the-pure-stiffness-hourglass-formulation-300x175.webp\" alt=\"Figure 8. The deformed mesh for the three-dimensional model using the pure stiffness hourglass formulation (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at the end of forming.\" width=\"300\" height=\"175\" srcset=\"https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-8.-The-deformed-mesh-for-the-three-dimensional-model-using-the-pure-stiffness-hourglass-formulation-300x175.webp 300w, https:\/\/kimeca.com.mx\/wp-content\/uploads\/2026\/04\/Figure-8.-The-deformed-mesh-for-the-three-dimensional-model-using-the-pure-stiffness-hourglass-formulation.webp 337w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/p>\n<p style=\"text-align: center;\"><strong>Figure 8. The deformed mesh for the three-dimensional model using the pure stiffness hourglass formulation (HOURGLASS=STIFFNESS) and the orthogonal kinematic formulation (KINEMATIC SPLIT=ORTHOGONAL) at the end of forming.<\/strong><\/p>\n<h2><span class=\"ez-toc-section\" id=\"References\"><\/span>References<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p>Industrieverband Deutscher Schmieden e.V. (IDS), \u201cForging of an Axisymmetric Disk,\u201d FEM\u2013Material Flow Simulation in the Forging Industry, Hagen, Germany, October 1997.<\/p>\n<p>[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=&#8221;1_3,1_3,1_3&#8243; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_column type=&#8221;1_3&#8243; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_button button_url=&#8221;https:\/\/3ds.com&#8221; button_text=&#8221;Dassault Syst\u00e8mes&#8221; admin_label=&#8221;abq\/xpl&#8221; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][\/et_pb_button][\/et_pb_column][et_pb_column type=&#8221;1_3&#8243; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_button button_url=&#8221;https:\/\/kimeca.com.mx\/index.php\/services\/educational-partner-simulia-catia-3dexperience-enovia-training\/training-simulia\/metal-forming-with-abaqus\/&#8221; button_text=&#8221;Metal Forming With Abaqus&#8221; admin_label=&#8221;curso&#8221; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][\/et_pb_button][\/et_pb_column][et_pb_column type=&#8221;1_3&#8243; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_button button_url=&#8221;https:\/\/youtu.be\/rI9UGPcuFO4?si=GIcbyZFSzDyuP8xA&#8221; url_new_window=&#8221;on&#8221; button_text=&#8221;youtube: An\u00e1lisis de Forja con Abaqus&#8221; admin_label=&#8221;youtube&#8221; _builder_version=&#8221;4.27.0&#8243; _module_preset=&#8221;default&#8221; global_colors_info=&#8221;{}&#8221;][\/et_pb_button][\/et_pb_column][\/et_pb_row][\/et_pb_section]<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Unlock the Secrets of Forging with FEA Manufacturing Simulation<\/p>\n","protected":false},"author":4,"featured_media":5446,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_et_pb_use_builder":"on","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":true,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2}},"categories":[46,34,36],"tags":[84,352,68,354,58],"class_list":["post-5433","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-abaqus","category-dassault-systemes","category-simulia","tag-simulia-abaqus-fea","tag-explicit","tag-fea","tag-forge","tag-simulia"],"jetpack_publicize_connections":[],"_links":{"self":[{"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/posts\/5433","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/users\/4"}],"replies":[{"embeddable":true,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/comments?post=5433"}],"version-history":[{"count":12,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/posts\/5433\/revisions"}],"predecessor-version":[{"id":5458,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/posts\/5433\/revisions\/5458"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/media\/5446"}],"wp:attachment":[{"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/media?parent=5433"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/categories?post=5433"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/kimeca.com.mx\/index.php\/wp-json\/wp\/v2\/tags?post=5433"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}