PSI - Issue 46

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Gaurav Singh et al. / Procedia Structural Integrity 46 (2023) 149–154 Gaurav Singh et al. / Structural Integrity Procedia 00 (2021) 000–000

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Fig. 1. (a) A schematic diagram of a swaging head (Ishkina et al., 2019) and (b) The zones of the swaging process (Zhang et al., 2014).

The primary focus was to design 8 different Die Designs with an increasing angle of 2 degrees. The initial die was given a die angle of 2 degrees, and subsequently dies with die angles of 4, 6, 8, 10, 12 & 14 degrees were designed. The die was given the following dimensions of 100 mm x 100 mm x 250 mm according to DIN8583 standard as shown in Fig 2(a, b).

Fig. 2. Schematic of Die Design used in the present study

2.3 Pre-Processing Parameters & Simulation Setup The integrated Manufacturing module of Deform 3D software was used for performing Swaging simulation of the test sample. A 3D finite element model based on plastic and elastic-plastic formulation is developed using the commercial finite element software DEFORM 3D (12.1, Scientific Forming Technologies Corporation Columbus, Ohio, Unites States) in the present work to analyse the residual stress in Zr-4 alloy. DEFORM 3D uses the finite element method to solve large deformation problems and an automatic mesh generator (AMG) to automatically provide an optimized remeshing capability. The preparation of the FEM model is extensive work and therefore followed a set of guidelines, parameters, and boundary conditions as a process, pass table (shown in Table 1) in the Deform 3D software. The following inputs were given to the Pass Table to process our simulation run as given in Table 1. A total of 6 passes were defined to