1. The document compares FEM analysis using Deform 3D and Solidworks software to model the upsetting process under sliding friction conditions. 2. A tribological test apparatus was developed that could measure normal and tangential forces during upsetting. Models of the apparatus were created in Solidworks and Deform 3D. 3. The results found that Deform 3D could better simulate the real deformed sample geometries compared to Solidworks. However, both programs provided generally similar results and are effective tools for simulating metal forming processes under different conditions.

1. 89
Volume 56
Issue 2
August 2012
Pages 89-92
International Scientific Journal
published monthly by the
World Academy of Materials
and Manufacturing Engineering
© Copyright by International OCSCO World Press. All rights reserved. 2012
Deform 3D and Solidworks FEM tests
in conditions of sliding friction
K. Lenik*, S. Korga
Department of Fundamental Technics, Lublin University of Technology,
ul. Nadbystrzycka 38, 20-618 Lublin, Poland
* Corresponding e-mail address: wz.kpt@pollub.pl
Received 02.06.2012; published in revised form 01.08.2012
ABSTRACT
Purpose: The aim of this study is to compare systems, modelling and FEM analysis for metal forming
on the example of upsetting conditions in a specially constructed tribological apparatus.
Design/methodology/approach: Modelling and analysis of the process of upsetting the traffic
conditions using the Deform 3D software ver. 10 and Solidworks 2010 - Simulation Module.
Findings: The paper presents a comparison of the results of tests conducted in real and virtual
conditions. It describes the adopted common features and different research methods.
Research limitations/implications: The research of sample upsetting in movement conditions
enables to determinate the effectiveness of accepted research methods.
Practical implications: Finite element method can be used as an effective tool for the study of
phenomena forming when considering different operating conditions of individual elements provided
the appropriate tools for FEA.
Originality/value: The use of sliding friction apparatus and FEM for plastic deformation processes
in research.
Keywords: FEM analysis; Tribological processes; Simulation for sliding friction; Plastic deformation
modeling
Reference to this paper should be given in the following way:
K. Lenik, S. Korga, Deform 3D and Solidworks FEM tests in conditions of sliding friction, Archives of
Materials Science and Engineering 56/2 (2012) 89-92.
METHODOLOGY OF RESEARCH, ANALYSIS AND MODELLING
1. Introduction
One of the problems of contemporary research and work on
the friction of tribological processes in terms of plastic deformation
of the elements of a selected pair of friction is the modelling of
both: laboratory experiments and theoretical calculations. This
implies the selection of appropriate research tools of numerical
analysis such as the finite element method. There are many
publication devoted to the study of the use of systems simulation
and finite element method in terms of tribological problems.
Because of the unusual nature of friction the conditions of plastic
deformation, it can be classified as an unconventional tribological
process [1, 2].
Having adopted the analysis of the complex nature of friction
and taking into account the specific conditions of plastic
deformation as non-conventional tribological processes, the aim
of this work was to compare the applicability of SolidWorks 3D
Deform in terms of establishing links between the preset values of
friction between resistance and the preset speed of the sample.
The scope of this paper is a compilation of results of tests
conducted by means of the software Deform 3D ver.10 and
SolidWorks 2010. The comparison is related to the choice of
model for the analysis of a particular process.
1. Introduction

2. 90 90
K. Lenik, S. Korga
Archives of Materials Science and Engineering
2. Results and discussing
The test developed at the Department of Fundamentals of
Technology position tribological enables tribological experiments
under conditions of the process of upsetting [3, 4]. Construction
of tribological furnishing is shown in Figure 1 The device consists
of two plates (1) and (2), to which are attached interchangeable
plates (6) and (7), between which, three test samples are placed.
It is surrounded by (8) including a removable rod (5) with two
screws (4) pivotally connected with the rod (5) and the plates (1)
and (2). Two tensometer gauges are glued on the rod (5) and on
the plate (2). Lateral surface of the sample is tangent with the
handle tie.
Fig. 1. Test stand layout
The laboratory consists of two plates, one upper and lower
second The upper plate is loaded by force interaction of
a hydraulic press while the bottom is stationary. During this time,
in the case modelling, the extrusion process is ejecting material
sample (3) placed between the plates (6) and (7). The measurements
of the normal and tangential forces are carried out using strain
gauges (9) and (10) and the measuring apparatus. The rate of
ejection of the sample (3) during compression is adjustable by
means of two screws (4) and the attached rod (5). The device is
provided with a set of plates (6) and (7) which are mounted in
plates (1) and (2). Allows ones to make measurements for materials
and samples with different physical properties. During the press
the reciprocating motion of the sample is forced through the
system and the connecting rod attached to the bottom and top
plates. The horizontal strain gauges register the amount of force
of the frictional resistance and of the horizontal movement of the
sample. The layout of strain gauges on the bottom plate enables to
register the pressure.
2.1. FEM research
In order to analyse the problem specific FEM has been
developed for a theoretical model of friction. Boundary conditions
concern the determination of the kinetics of association between
elements of the traffic study, the dynamics of load, speed of
movement and characteristics of materials [5, 6]. The performed
numerical analysis allows for the individual consideration of the
phenomenon under investigation but using Deform 3D system
requires advance preparation of input files to the initial conditions
such as geometry. With this assumption the paper is based on
models developed in SolidWorks for simultaneous application to
the calculation of the mesh in the package Deform. This means
that working model position shown in Figure 2 deals with the
calculation in both programs. Using the virtual device model is
based on the use of STL files. The files for FEM analysis has been
prepared in SolidWorks 2010. The view of the test apparatus
model shown in Figure 2.
Fig. 2. The view of the working part of the test in section prepared
in SolidWorks
The developed simplified model approximates the position of
the actual conditions for the processes studied in both programs
identified. The same boundary conditions have been identified.
The investigated phenomenon analysis used the models of
working parts constructed in SolidWorks software.
The degrees of freedom and the forces affecting the objects of
the device is shown in Fig. 3.
a)
b)
Fig. 3. Views of the devices with interactions: a) SolidWorks,
b) Deform 3D
2.1. FEM research
2. Results and discussing

3. 91
Deform 3D and Solidworks FEM tests in conditions of sliding friction
Volume 56 Issue 2 August 2012
Figure 4 presents the examples of changes in geometry of
samples obtained in the test process. The shades of grey marked
the stress distributions. In reality, the program gives stress results
in a colour gradient. Carrying out the calculations results in a series
of graphs. The model of stress distribution is shown in Figure 5.
a)
b)
Fig. 4. Stress distribution in the sample using: a) SolidWorks,
b) Deform 3D
Fig. 5. View of the tribological and the deformed sample
The working unit model together with the arising deformation
of the sample is shown in Fig 5. As follows from the obtained
results, Deform 3D program allows a much greater extent to
obtain the geometry of the samples corresponding to the actual
shapes of the samples obtained in experimental studies. This
means that the individual nodes of the sample in the vertical and
horizontal directions are closer to the received samples. The
variability of the system location in a complex set of traffic
depending on the instantaneous changes in vertical and horizontal
components remains to be solved [7-9].
Shown in Figures 5 and 6 relate to movement of the material
displacement of nodes in the previously discretized grid.
a)
b) c)
Fig. 6. Approximate view of the deformed sample: a) SolidWorks,
b) Deform 3D, c) the laboratory
Fig. 7. Velocities characteristic of the sample displacement changes
in time

4. 92 92 READING DIRECT: www.archivesmse.org
The supplement for the received data is to change the speed
characteristics of the sample displacement (identifying the model
with reality). For example a constant feed rate was achieved as
confirmed in Figure 7 [10-14].
3. Conclusions
The presented processes of the use of Deform 3D and
SolidWorks determine the desirability of both systems in the
analysis of complex processes such as sliding friction with the
effects of plastic deformation of the material. The obtained results
indicate the possibility of effective use of both systems for FEM
calculations. Deform 3D allows for testing in a broader scope,
including the boundary conditions which is not available in
SolidWorks simulation package. The results obtained from two
analysis and from the research are close to each other. However,
the sample examined in the Deform 3D much better complies
with the appearance and dimensions of the samples from the
laboratory stand. The use of dedicated research enables that
forming the processes can reliably reproduce the behaviour of the
sample. The difference between the obtained results indicate that
FEM is an alternative test for metal forming processes. Such
studies provide control over the parameters of the analysed
process the accepted test stand and the research methodology
allow to assess the movement in the test node of sliding friction.
The issues discussed in the work can be used in a wide range for
multiple tests under varying process conditions.
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3. Conclusions