RR Manual All

SHAPE-RR
User’s Manual
Solutions for
Highly
Advanced
Process
Engineering
SHAPE Co., Ltd.

www.shape.co.kr
SHAPE-RR
U
Usseerr’’ss G
Guuiiddee M
Maannuuaall
Solutions for Highly Advanced Process Engineering
I. Introduction
I.1. Introduction of Ring Rolling Process
Ring rolling is a specialized form of rolling process for manufacturing seamless ring. On a typical ring rolling
machine, a ring shaped blank is expanded to a desired final diameter and is formed to have a desired cross section
by using two sets of rolls. The radial set of rolls controls the radial thickness of the ring, while the axial roll and an
idle pressure roll (mandrel). By keeping the driving roll axis stationary, the pressure roll is driven radially toward
the driving roll and the main deformation of the workpiece occurs in the radial gap leading to an increase of the ring
diameter. The axial rolls are tapered in order to reduce the velocity difference between the surface of the rolls and
the workpiece.
This process is widely used in many industrial fields. The advantages of ring rolling are short production time,
uniform quality, closed tolerance, and considerable saving in material cost.
Although the ring rolling process is similar to plate rolling, there are some significant differences that make it
inappropriate to apply the analytical method of the conventional plate rolling process to ring rolling. First, work
piece has a curvature and its radius change continuously. Second, diameters of the driving roll and the pressure roll
are different. Third, pressure roll is idle and advanced to the driving roll side continuously. Forth, metal flow is
three-dimensional. For these reason, designing of the ring rolling process has long been done only through
experiments, experience.
I.2. Introduction of SHAPE-RR

In 1990, The CEO and president of SHAPE, professor Nak-soo Kim developed the first full-3D FEM solver in
the world. He simulated plain and T-shape ring rolling process when he worked at ERC/NSM in the Ohio State
University. “SHAPE-RR” program developed with the full 3D FEM solver. Furthermore, we improved the solver
and add many functions for designing roll and pre-form (or blank) of ring rolling process. Optimize the quality of
your final product already prior to manufacturing by using the first simulation solution for the ring rolling process.
Until now there is no proper material flow simulation program which allow to analyze the whole three-
dimensional ring rolling process with exact calculation. Now SHAPE show you an attractive ring rolling software.
This software allows you to simulate and test the usability of a new set of rings on the screen and to modify it
accordingly in case of too high inner material strain. The “virtual” ring rolling roll checks the function of the
complete set of rolls in a sort of test run-a crucial advantage for the user.
In order to develop such complicated products, the designer has to identify possible sources of errors at a very
early stage, if possible before physically manufacturing the products, in order to integrate the necessary design
adaptations already in the pre-manufacturing phase. Don’t afraid about this new software usage. If you have a basic
ring rolling knowledge and a hand to click mouse, it must be a piece of cake. SHAPE-RR is for engineer yourself.
I.3. About This Manual

The goal of this manual is to help the users who are not used finite element method software to successfully
simulate a ring rolling process. All steps will be introduced step by step, so the user is guided through the entire
process. After having worked through this user’s manual, you will be able to do the analysis of ring rolling process
and feel the power of finite element method. To get a flexible manual quickly leading to the most important points
some symbols with following meaning have been introduced
1 I. Introduction
II. Basic Theory
II.1. Velocity Field
The three-dimensional simulation of the ring rolling process is divided to two different procedures. One is to find
the velocity field in the current configuration of workpiece(ring) and the other is to update the geometry of the
workpiece according to the velocities found. The workpiece is represented numerically by a ‘mesh system’ which
consists of ‘nodes’ and ‘elements’. The velocity field can be found by the rigid–plastic finite element method needs
iterations to find converged velocities at nodes. Once the velocities are calculated for the given geometry and the
boundary conditions, the mesh system can be rotated(of course, numerically!) accompanying its own shape changes.
This numerical procedure is called ‘updating’ of the mesh system.
II.2. Mesh System
Two kinds of mesh systems are used for the simulation. Actual Mesh System(AMS) is a mesh system fixed to the
workpiece. It stores every information on the material of the workpiece, e.g., geometry of the workpiece
(coordinates of the nodal points), history of plastic deformation (total effective strain), etc. Spacial Mesh
System(SMS) is a mesh system fixed in the space but changing its geometry according to that of the AMS. The
SMS keeps providing velocity field for the given geometry by the finite element method.
By increasing two kinds of mesh systems, unnecessary computations to take each node’s boundary changes into
considerations in the normal rigid plastic FEM are avoided. SMS can be constructed with fine meshes in the main
deforming zone and rough meshes in the understanding almost rigid zone. Hence it saves the computing time
enormously.
Fine mesh in
Rough mesh in
deforming zone
rigid zone
( Actual Mesh System ) ( Spacial Mesh System )
Fig.II.1 Mesh system
1 II. Basic Theory

II.3. Rigid Plastic Finite Element Method
II.3.1. Domain of workpiece
The configuration of a body occupies the space V at a given time t(see Fig. II.2). Velocity is prescribed on the
surface Sv and traction is prescribed on the surface Sf. Total surface is composed of Sv and Sf. If the material points
in the body follow the law of linear momentum conservation, we can apply so-called equations of motion to the
particles. If the acceleration term and body force term are neglected compared to the stress gradient term, we obtain
the following equations of equilibrium.
∂σ ij
=0
Equilibrium equation : ∂x j in V
II.3.2. Boundary conditions
The boundary conditions to the body V can be divided into two types.
σ ij n j = t i = t i∗
Traction B.C. : on Sf
∗
vi = v i
Velocity B.C. : on Sv
Numerically, traction B.C.’s are called to “suppressible” B.C.’s and velocity B.C.’s are called to “natural” or
“essential” B.C.’s.
Fig.II.2 Boundary condition
2 II. Basic Theory

II.3.3. Governing equations
The problems are limited to quasi-static and infinitesimal deformation based on the rigid-plastic approach in the
formulation. The inertial effects, body forces, and changes in geometry due to deformation are neglected. Then the
velocity and stress fields satisfy the following conditions.
(i) Equilibrium equations
σ ij , j = 0 (2.1)
(ii) Boundary conditions
v i = vi on SU ⎫
⎬S + S F = S Total
σ ij n j = t i on SF ⎭ U (2.2)
(iii) Flow-rule (constitutive equations)
ε&
ε&ij = 3
σ ij′
2
σ , (2.3)
where
1 1
ε& p = ( 23 ε&ijp ε&ijp ) 2 and σ = ( 32 σ ij′ σ ij′ ) 2
(iv) Relationship of strain rate-velocity (compatibility equation)
ε&ij = 12 (vi , j + v j ,i )
(2.4)
(v) Incompressibility
ε&kk = 0
(2.5)
(vi) Flow stress
σ = σ (ε , ε& , T )
(2.6)
3 II. Basic Theory

III. Overview of SHAPE-RR
III.1. Simulation Procedure
III.1.1. Assuming contact
Actually exact contact is impossible in the finite element method. Within a scheduled margin of error, assuming
roll and workpiece are contact.
III.1.2. Updating the AMS
The velocity of the AMS nodes is obtained by linearly interpolating those of the SMS nodes. From the
interpolated velocities, the displacements in the AMS during the time dt are calculated. In SHAPE-RR, to deal with
a large time increment in a step, the angular velocity of a material point is always found as a linearly interpolated
value from those of the SMS nodes. We can represent a material point of the workpiece, or AMS as P and
neighboring special points, or SMS nodes as A and B.
Fig.III.1 Updating AMS
4 III. Overview of SHAPE-RR

III.1.3. Updating the SMS
The θ-direction of the position vector of the nodes in the SMS is fixed and the positions of nodes change only in
the r- and z- directions. The nodes in the SMS are reconstructed based on the AMS of which geometry and material
property are already updated from the velocity field in the SMS.
Fig.III.2 Flow chart
Each node in the SMS is interpolated from the nodes in the AMS. To relocate the nodes in the SMS, first, the
neighboring nodes of the AMS should be found.

III.1.4. Updating the ring center
As the process progresses, the radius of the ring increases, the position of the ring center changes. In order to
determine the location of the ring center, the following three steps are used.
Step1: Updating ring center by velocity field
Step2: Adjusting ring center by the volume constancy
Step3: Locating the geometry
III.1.5. Updating the rotating axles
SHAPE-RR transforms rectangular coordinates to get exact answer, because a ring is inclined (x, y, z coordinates
→ x, y’, z’ coordinates ). Rotating axles update and return 3.2.1

III.2. Overview of SHAPE-RR Windows
Menu bar: Consist of File, Pre-Process, Solution, Post-Process, Feature, Frame, Tool, View, Window, Help.
Icon Tool bar: Several icons are shown in this icon tool bar which use SHAPE-RR
Main Display Window: Workspace

bar
Results of workpiece are displayed in this window
Information
bar
Output bar: The message from the solver

is listed up while doing the simulation.
Fig.III.3 SHAPE-RR Windows
• Workspace bar
Information of whole passes and roll can be checked.
• Information bar
Display information of selected points as a color

III.3. Setting Preference
Setting preference of SHAPE-RR can be selected a command from the File pull-down menu.
Fig.III.4 Preference menu
Setting preference consists of four folders such as basic, directories, window styles, and hardware summary.

III.3.1. Basic
Basic offers several settings for SHAPE-RR.
• Screen color: It is fixed as 32bit to the all situation when 17” monitor used.
• Rendering context color: It has variables that’s in monitor, so Screen Dependent is strongly recommended.
• Z(depth)-buffer: This option enable to express rich color.
• Enable double-buffer: This option increases analysis speed.
• Accelerated by a device driver: This option offers VGA acceleration.
Fig.III.5 Basic tab

III.3.2. Directories
Directories preference enables to change directories which want to save. To change saving directories or location,
click Browse.
Fig.III.5 Directories tab
If user wants to change directory, select directory where under the Temporary Working Directory. In there,
select Browse to change directory.

III.3.3. Windows style
Windows style preference enable to change color, font and size of windows. In this preference only workpiece,
information bar and output messages can be changed.
Fig.III.6 Windows Styles tab
Fig.III.7 Changing color

III.3.4. Hardware summary
Hardware summary preference gives graphic information. There is nothing to change values, just giving
information.
Fig.III.8 Hardware Summary tab
Note) In this preference menu, default values are recommended.
Note) You can designate your working files to appropriate folders by selecting them in the Directories folder of
Preference window.

III.4. Using The Mouse to Control Object
The mouse buttons have a consistent use in SHAPE-RF pre- and post-processors to control the objects in the main
display window. The Alt + Right button is used for rotating an object; Left and Right mouse button is for
translating the object.
The usage of mouse button Keys and hot key are explained at Table 1. The some hot keys are available only when
Auto Focusing is not active.
Table 1 Use of "hot keys" and mouse button
Key Mouse Button Action
Alt Right Rotation about an arbitrary axle in space

Ctrl Right Rotation about Z-axle
Panning in arbitrary direction (if Auto-
Ctrl Left
focusing turned off)
Panning in arbitrary direction (if Auto-
Left+Right
focusing turned off)
Shift Right Zoom in or out(if Auto-focusing turned off)
Up scroll: zoom in
Wheel
Down scroll: zoom out
Alt+1 Displaying the object in isometric plane
Alt+2 Displaying the object in X-Y plane
Alt+3 Displaying the object in Z-Y plane
Alt+4 Displaying the object in X-Z plane
Change the canvas plane to X-Y, Y-Z, Z-X
Ctrl+1
plane by turns
Ctrl+2 Change the canvas plane to X-Y plane
Ctrl+3 Change the canvas plane to Y-Z plane
Ctrl+4 Change the canvas plane to Z-X plane

IV. Pre-processing
Pre-processing is for preparing the data set so that the solver has all the needed information to simulate a ring
rolling process. SHAPE-RR is a three dimensional FEM package highly oriented user and process. Windows used
in SHAPE-RR is almost closed to Microsoft programs which users are used. Therefore, SHAPE-RR pre-processing
consists of step-by-step procedure. Because it is only for ring rolling process, there is no extra process condition
setup.
The usual finite element simulation needs complicated “mesh”, which models the workpiece numerically. Also, it
needs material properties and process parameters. But in the SHAPE-RR pre-process, auto mesh generation is
offered. Also user define is possible. So, preparing the input data is so simple and easy that even a beginner can be a
master of the SHAPE-RR pre-processing in a moment.
IV.1. Getting Started
IV.1.1. New Project
To start up SHAPE-RR, double click the icon of SHAPE-RR, .
Fig.IV.1.1 New menu
Sure, there is nothing because any file is not opened. Click icon (or File>New), to open empty project. Select
the process type and click OK
Fig.IV.1.2 Selection of Project Type
14 IV. Pre-processing
Fig.IV.1.3 New project
IV.1.2. File Opening
The files which is available to SHAPE-RR are RRI, RSF files. The file having extension RRI is the input
file for simulation. The file having extension RSF has the results of steps.
To open an existing SHAPE-RR file, you can select Open from the File menu. You can also open files by
dragging them from Windows Explorer into SHAPE-RR. If you drop one or more drawings anywhere outside the
drawing area, for example, the blank space next to the toolbars, SHAPE-RR opens the drawings.
You can double-click a drawing in Windows Explorer to launch SHAPE-RR and open files.
IV.1.3. RRI Opening
The RRI file has the information of geometry and the various conditions for solving.
It can be generated by Export from File menu. Although the project is started empty by New menu, the
RRI file is generated automatically by SHAPE-RR before solving.
Fig.IV.1.4 RRI open
Fig.IV.1.5 Export RRI
IV.1.3.1. RSF Opening
The RSF file has a lot of results of steps. If you open the RSF file, the Out-put file open dialog box will
be shown as Fig.IV.1.6. You can see the list of included steps. Then you can select files you want to open. While
SHAPE-RR is solving, you can also select the mesh-system to be opened.
Fig.IV.1.6 Opening out-put files
Click OK, then the files selected will be opened shown as Fig. IV.1.7.
Warning) If too many steps opened, the software will be put pressure upon, and even may be done not response.
Fig.IV.1.7 RSF open
Note) The results file extension of SHAPE-RR changes to RSF. But RRS, UNV file which is previous that of
SHAPE-RR is still available.
Fig.IV.1.8 Changing mesh system Fig.IV.1.9 Import Result Step
If you want to append other steps to current project, use the Import from the File menu.
For examples, If you want to append results of two steps, select same RSF file with same mesh-system.
Fig.IV.1.10 Selection of steps
Then the results of two steps will be appended to current project as shown Fig.IV.1.11.
new imported steps
Fig.IV.1.11 Appended steps
IV.1.4. Coordinate System
SHAPE-RR has two sub-work modes, Primary Layer and Drafting Layer in Design mode.
In Drafting layer mode, drawing process is executed. For example, importing roll and ring, register ring and roll.
Other almost processes are executed in Primary layer mode.
SHAPE-RR basically gives XYZ coordinate, as followings.
IV.1.4.1. Primary Layer
The default coordinate system of Primary Layer is yz plane as follow figure.
Y
X
Fig.IV.1.12 Coordinate system in Primary Layer
IV.1.4.2. Drafting Layer
The default coordinate system of Dafting Layer is xy plane as follow figure.
X Y
Fig.IV.1.13 Coordinate system in Drafting Layer
IV.2. Import Geometry
CAD data only can be imported by DXF/IGES format as mentioned before.
IV.2.1. Draw ring and rolls in the CAD software
If the project is first stage, drawn CAD files could be needed. But three things should be considered in the
CAD software to export. First, CAD files must be saved as DXF/IGES file format. DXF file means Data exchange
Format, and IGES file means Initial Graphics Exchange Specification. They are a standard format describing data.
Second, CAD data of ring and rolls should be drawn on the XY plane, even though both ring and rolls are seen YZ
plane in the SHAPE-RR. Third, base point of ring and main roll had better be matched. But there is no fixed base
point, it is up to user’s preference. In this example, base point of ring and main roll are shown next page.
Note) AutoCAD R12/LT2 DXF version may occur errors when imported.
Note) The IGES file can be imported without distinction of IGES version. But currently the dataset number is
restricted. The available dataset number is only 106, 110, 126.
IV.2.2. Base point
Base point of ring and rolls had better be matched for reducing the step of pre-process in SHAPE-RR.
When there is no fixed base point, it is up to user’s preference. But it is important that it is concerned with rotating
center (rotating center is mentioned in the Radial section properties later) which determines ring’s outer diameter.
Fig.IV.2.1 Base point
Ring and main roll’s base points are combined in the SHAPE-RR as following figure. These two points
had better be matched to each other. Generally it is proposed that the base point be same as the origin point of
coordinate system, (0.000,0.000,0.000).
Base
Fig.IV.2.2 Base point in SHAPE-RR
IV.2.3. Draw ring in the CAD software
CAD data of right side ring profile should be drawn. You do not need to draw whole ring, just draw right section
of the ring. SHAPE-RR automatically converts two-dimensional section into three-dimensional ring. On the
coordinate system of SHAPE-RR, the section to be drawn is on Y-Z plane. But you should note that the section
must be drawn on X-Y plane with CAD software as shown Fig.IV.2.3. Fig.IV.2.4 shows the drawing describing a
ring in AutoCAD.
Fig.IV.2.3 Right section of ring
Fig.IV.2.4 Drawing ring profile
The ring geometry must have a continuous ring profile and a center mark. But if
the base point is same as base point on CAD, the center mark does not need any more. It is important that the scale
of dimension must be same. That is 1:1. The dimension of the drawing retains to SHAPE-RR.
IV.2.4. Draw rolls in the CAD software
As drawing of ring profile, CAD data of right side roll profile should be drawn. The roll must be described to Y-Z
plane profile taken half geometry in SHAPE-RR because on the coordinate system of SHAPE-RR, the section to be
drawn is on Y-Z plane. But you should note that the section must be drawn on X-Y plane with CAD software as
shown Fig.IV.2.5.
Fig.IV.2.5 Section of roll on Y-Z plain in SHAPE-RR
Fig.IV.2.6 Roll profile
The roll geometry must have continuous roll profile(s), axle profile(s). The line entity describing axle
must be longer than each ends of roll profile shown as Fig.IV.2.6. If the geometry is laid on the coordinate of the
base point, the center mark does not need any more.
In the same case as ring, the scale of dimension must be same. The dimension of the drawing retains to
SHAPE-RR. Although a drawing has many roll geometry, only one roll data can be imported at once. You should
note that currently the roll drawn within one axle can be only imported. Fig.IV.2.7. shows a drawing describing two
rolls in AutoCAD.
Fig.IV.2.7 Drawing roll profile
IV.2.5. Import geometry files
To import CAD data, SHAPE-RR is in Drafting Layer mode. After changing layer mode to Drafting
Layer, select Design >> Import Geometry. And find CAD files in the directories.
Fig.IV.2.8 Import Geometry
Fig.IV.2.9 Import DXF file
Fig.IV.2.10 Import IGES file
IV.2.6. Import Roll
To import roll set data, click Roll geometry.
Fig.IV.2.11 Roll geometry type
The Margin error of geometric calculation is to define geometric error. It must be considered to import
successfully. If the scale of dimension of the drawing is large, it needs large margin error vice versa.
If you want to change margin error, click Setting button.
IV.2.6.1. Margin of Error
Fig.IV.2.12 Margin of error
• Radius of circle to be regarded as a same point: If the edge point of any entity is in the circle having this radius
at the edge point of neighbor entity, then the two entities are regarded as being attached each one of two edge points
of an entity.
• Tolerance of length: A margin error for comparison of length.
• Tolerance of angle: A margin error for comparison of angle.
IV.2.6.2. Others
• Significant decimal point to be preserved: It is to prevent against a propagation of error while CAD calculation
as a preservation data down to this significant decimal point.
• Significant decimal point to be truncated: It is to ignore data up to this significant decimal point while
distinction of data between nontrivial and trivial.
After clicking OK, Import Geometry window appears.
IV.2.6.3. Import Information of Geometry
You can define or change the properties of object to be imported.
Fig.IV.2.13 Import information
Note) The screen of Import Geometry can be controlled with manipulating mouse controller like below table.
Mouse Controller Function

Left & Right Button Translation
Scroller Scaling
• Object list
It shows rolls to be imported. Also you can verify the properties of roll.
• Profile table
SHAPE-RR uses the simplified method which describes geometric profile of section of roll or ring. It is
available when all points are on same plane. In Fig.IV.2.14, the curve is consisted of three lines and two arcs on X-
Y plane. The curve can be described as P1 - P3 - P6 - P8. In where, P3 and P6 are include the radius value of arc in Z
coordinate.
P6 P7
P1 R1 P5
P8
y P2 26
R2 IV. Pre-processing
P4
x P3
Fig.IV.2.14 Description of profile
The profile table is just to show geometrical roll data. It is impossible modify roll data in this window.
Hide useless points option is to show or hide the bound points between line and arc entity. For example, in
Fig.IV.2.14, if it is checked the curve can be described as P1 - P3 - P6 - P8. If it is unchecked the curve can be
described as P1 - P2 - P3 - P4 - P5 - P6 - P7 - P8. Relative coordinates option makes transform the coordinates of
profile to the local coordinates which the origin point is a start point of axle and the X axis is the line that is from
start to end point of axle.
Fig.IV.2.15 Local Coordinates
Fig.IV.2.16 Global Coordinates
• Show table
If it is unchecked, the information, the coordinate of a mouse cursor and the number of each entity, will
be hidden.
Fig.IV.2.17 Hiding table
IV.2.6.4. Modification of roll geometry
The roll geometry can be modified by Roll Profile definition. The geometry modification function is operated in
Drafting layer.
The sequence of modification is as follow.

; Select the ‘Axle-**’ in workpiece bar which is needed to modify on ‘Primary Layer’ mode. Then ‘Axle-**’ is
activated, in blue line.
Click the right button of mouse, and menu window appears as Fig.IV.2.18.
Fig.IV.2.18 Modify “Axle-**” Profile menu
Selecting the modification menu, ‘Modify “Axle-**” Profile’, the layer mode is changed from Primary layer to
Drafting layer.
Click the “Design>>Roll Profile Definition” for modification of roll profile.
Fig.IV.2.19 Roll Profile Definition menu
Modify the values of x, y, Radius as following Fig.IV.2.20.
Fig.IV.2.20 The modification of roll geometry
IV.2.6.5. Register Roll
This process is to transfer coordinate system from xy plane(coordinate system of initial importing geometry) to yz
plane.
P1
P2
Fig.IV.2.21 X-Y plane Fig.IV.2.22 Y-Z plane
Fig.IV.2.23 Register Axle of Roll
• Axle start
The coordinate of the start point of a new axle (P2 in Fig.IV.2.22) is automatically imported as that of original CAD
drawing. For example, if P1 is (x1, y1, 0) in original CAD drawing, then P2 is (0, x1, y1).
If you want to remember coordinates of start and end points of an importing roll axle, refer the following sentence.
You can know those in importing process. Point the end point of axle with mouse in import geometry window, then
its coordinate is shown in a left upper window as bellow figure.
Coordinate of Axle
P1
Fig.IV.2.24 Coordinate of Axle
• Direction Vector
After appointing of axle start point, the direction vector should be appointed. Direction vector shows a direction of
axle. So its magnitude is indifferent.
If start point of axle and its direction vector is appointed, the end point of axle is fixed.
Press OK, then roll appears in main window as Fig.IV.2.25
Fig.IV.2.25 Roll feature after Roll Register
IV.2.7. Import Ring
To import ring profile data that already made in CAD program, select Section profile geometry. Other
things are same as Roll geometry.
Fig.IV.2.26 Section profile geometry type
Press ‘OK’, when above options are completed. Then you can see as below, Fig.IV.2.27.
Fig.IV.2.27 Type of symmetry
IV.2.7.1. Register Preform
After ring geometry is imported, register that.
Fig.IV.2.28 Register Preform Menu
Click the Design>>Register Preform, then follow window appears.
Fig.IV.2.29 Register Preform window
• Type of symmetry :
Type of symmetry is for selecting what ring is XY plane symmetric or asymmetric. This option is important for
setting boundary condition later.
• Rotation axle :
Rotation axle is driving axle of ring. Type the proper values.
• Move perform profile along with axle :
Unchecked : If you change the values of rotation axle, then ring size is changed.
Checked : Although you change the values of rotation axle, ring size is not changed but is translated as axle
translated.
Fig.IV.2.30 shows a feature which is imported two rolls and a ring.
Fig.IV.2.30 Imported feature
Note) If the ring pre-form is not seen, check ring pre-form icon activated or not. Also if the rolls are not seen, check
roll icon activated or not.
Fig.IV.2.31 Show and hide icon of the rolls
Fig.IV.2.32 Show and hide icon of the preform
Note) If the pre-form of ring and rolls are seen many-sided, check customised style in the Feature pull down menu.
The number of subdivisions along the Z axis has values between 12 and 180.
Fig.IV.2.33 Imported feature
Fig.IV.2.34 The number of subdivisions along the Z axis: 50
Fig.IV.2.35 The number of subdivisions along the Z axis: 12
IV.3. Preparation For A Running Solver
IV.3.1. Initial section profile
SHAPE-RR supports a mesh generation of section profile of preform automatically. To use this function,
you must do sampling for section layout and assign density for sampled points. Also you can import section mesh
from *.UNV which is created by IDEAS.
IV.3.1.1. Using auto mesh generation
Click the menu of Initial section profile in the pull down menu of Pre-process, then Sampling of the
section lay-out window appears. Default value is shown as bellows. Because mesh of default value is coarse, mesh
is divided more fine.
Fig.IV.3.1 Initial Section Profile menu
Fig.IV.3.2 Sampling points of lay-out
Note) The screen of Import Geometry can be controlled with manipulating mouse controller like below table.
Mouse Controller Function

Left & Right Button Translation
Scroller Scaling
• Dividing Entity
Select the Sampling and No operation, if you want divide node evenly. Point line where user want to
divide node, and line is activated. Then click twice to divide.
Fig.IV.3.3 Dividing entity
• Create & Erase describing points

To create node manually on the line, select Create radio button and point where want to make node.
Fig.IV.3.4 Creation of
sampling point
To erase node on the line, select Erase radio button and point where want to remove node.
• Rotating center
Rotating center means ring’s

rotating center. But it is not always
mean ring’s diameter. Ring’s diameter
also depends on where user sets ring’s Fig.IV.3.5
zero point. Rotating center
• Sampling Condition
Fig.IV.3.6 Sampling condition
Sampling condition show two kinds of option. First, Total number of points shows how many nodes are
selected. Second, Minimum Length of # is minimum length of element.
Click OK to finish initial section profile.
IV.3.1.2. Importing section mesh
You can import the section mesh from UNV file which is created by IDEAS. It can be realized through Import
Geometry menu.
Fig.IV.3.7 Import geometry menu
IV.3.2. Boundary condition
Boundary condition is for limiting movement of nodes. This is only under Symmetric condition of ring
section. If ring section of XY plane is asymmetric, skip boundary condition.
Fig.IV.3.8 Boundary Condition menu
In the SHAPE-RR, user only changes boundary condition as Not translate to Z direction in case of ring profile is
XY plane symmetric because others are physically useless.
Default condition is Free. If user wants to change Not translate to Z direction, select nodes with
dragging mouse which on the neutral axis.
Fig.IV.3.9 Definition of boundary condition
Note) Unless nodes are selected, click Filter icon in the Tool full down menu. That is not because there is no nodes
or bug, but because no object type can be selectable.
Fig.IV.3.10 Filter menu
Set selection Filter appears.
Fig.IV.3.11 Setting selection filter
Select an object that you want to select in Object List and click icon. Selected object moves
from Object List to Selectable. If you want to select all objects in Object List, click icon. (No need to
select any object in Object List). The selection of object(s) can be deselected by clicking the icon or
icon.
IV.3.3. Radial Section Properties
Radial section property is the most important in the pre-process and easy to make mistake. In this reason
user must be aware of Radial section property menu perfectly.
Radial section property is for making elements to simulate finite element method.
Fig.IV.3.12 Radial Section Properties menu
After clicking Radial Section Property menu, users meet as following figure. In the Radial sections box,
users can define number of AMS and SMS.
Note) About AMS and SMS, mentioned in the chapter II.2 Mesh system.
Fig.IV.3.13 Properties of radial sections
* Properties of Radial Sections
- Default value of Number of radial section of AMS is 180

- Default value of Number of radial section of SMS is 30.
- Number of angular symmetry :
It means number of symmetric deformation area in workpiece.
Number of angular symmetry : 1

Start angle of radial section : 90o
- Start angleθ( ) of radial section of SMS : Default value 0o

For convenience of seeing the cross section of deformation area, you had better set this value to 90o.
Number of angular symmetry : 3

Start angle of radial section : 0o
2
0o
-Value of Y axis of initial rotation center of perform is same as Rotation center of workpiece in the Initial section
profile menu.
Fig.IV.3.14 Rotation center
IV.3.3.1. Number of Radial Section of AMS
Fig.IV.3.15 Actual mesh system
Number of radial section of AMS means how many elements in the 360 degrees. If user type “180”, it could mean
that elements are made every 2 degrees evenly.
IV.3.3.2. Number of radial section of SMS
Fig.IV.3.16 Spatial mesh system
Default value of Property of SMS is Manually generate the radial section mesh. This option divides meshes
manually that’s in cases. Currently, Automatically generate the radial section mesh option is not supported.
Fig.IV.3.17 Property of SMS
Number of radial section of SMS also means how many elements in the 360 degrees. But SMS mesh
system is not evenly divided by degree. SMS has coarse mesh in the rigid zone, by contrast fine mesh in the
deforming zone. In this reason, meshes are divided manually in the SMS.
In this user’s manual from 90 degree to 120, it assumed as deforming zone. So user divides mesh finely
in this zone. At first there is nothing in the Boundary condition of radial section of SMS, so proper number should
be typed.
After selecting angle 90 and 120, click left mouse button. Then simple box which Boundary condition,
Insert, Divide, Delete is shown is appeared. In there, select Divide to divide meshes finely.
Now, divided angles are shown as following figure.
[Preprocess -> Radial section property]
Select the region to divide, this region will be deformation region.
Click the Divide button, and number of dividing value (in here 10)
The region of 90o~120o is divided by 10 pieces.
Fig.IV.3.18 Dividing angle of SMS
Note) Number of radial section of SMS is not assumed under specific information. So Number of radial section
of SMS has variable value that’s in pressure roll size compare to ring. But usually between 90° and 120° are
guessed as deforming zone.
IV.3.3.3. Change Boundary Condition
Already boundary condition is mentioned about symmetric problem, and in the Radial section
properties boundary condition is totally same concept. It is for limiting movement of nodes. Boundary condition
menu is only for symmetric condition. Contrastively Boundary condition of radial sections of SMS is not
concerned with symmetric. So this procedure is essential, not optional.
As being mentioned before, Number of radial section of AMS is not concerned with calculating time.
Calculating time is only depends on how many number of radial section of SMS. Sure, fine mesh gives more
accurate result, takes more time.
[Preprocess -> Radial section property]

After dividing the radial section, you should set up the boundary condition of each sections which are predicted to
be deformable area.
Select the divided region in table, and click the condition button
Fig.IV.3.19 Boundary condition menu for SMS
Check the Belongs to deforming region, number,
in Contact selection window and insert number 1….
If roll is clamping roll, this value becomes 0(zero), or not integer which is bigger than zero. (refer to IV.3.5 Roll
Property)
Fig.IV.3.20 Contact conditions
Boundary condition of deforming region has changed.
Fig.IV.3.22 Radial section properties
Click OK, then you can verify the pre-estimated SMS if the radial section mesh is generated manually
and Pre-estimated SMS icon is active.
Fig.IV.3.23 Pre-estimated SMS icon
Fig.IV.3.24 Pre-estimated SMS
IV.3.4. Material properties
You can define the material properties as form of flow stress equation. Currently the SHAPE-RR contains only one
flow stress model, exponential hardening model.
IV.3.4.1. Flow stress equation
Fig.IV.3.25 Material properties: Flow Stress Equations
The flow stress of a material is a function of strain and stain rate in cold forming. Therefore, the flow stress (σ) of a
material is assumed to have the following relation,
σ = K 0 (a 0 + a1ε ) a (b 0 + b1ε& )b
2 2
If you have some experimental data such as UTS (Ultimate tensile stress), Yield strength(Y0), SHAPE-RR can
convert the known parameter to the flow stress.
Fig.IV.3.26 Stress-Strain Curve for Table 2
Table 2 used properties in Fig.III.10.
Steel Aluminum
Y0 800 Y0 340
a2 0.2 a2 0.13
a1, b0 1 a1, b0 1
a0, b1, b2 0 a0, b1, b2 0
<Example>
A strain-rate sensitive material with the flow stress
Y0 A0 a1 a2 b0 b1 b2
8.15 1.0 0.0 0.0 0.0 1.0 0.094
Perfectly plastic material should be like this
Y0 A0 a1 a2 b0 b1 b2
1.0 1.0 0.0 0.0 1.0 0.0 0.0
IV.3.4.2. Mechanical Properties
Fig.IV.3.27 Material properties: Mechanical Properties
• Physical properties
Young’s modulus (Mpa)
Poisson’s ratio
Maximum plastic strain
Yield Strength(Mpa)
Ultimate tensile strength(Mpa)
• Heat properties
Thermal conductivity (N/sec-K)
Heat capacity (N/mm2-K): (mass density x specific heat)
Friction of plastic work converted to heat
IV.3.4.3. Material Database
SHAPE-RR allows you to make your own material database as following figure.
Fig.IV.3.28 Material properties: Material Database
• Material:
name of material
• Flow stress equation

σ = K 0 (a 0 + a 1ε ) a (b 0 + b1ε& ) b
2 2
Type : Type 2 is the equation, .

K[Mpa] : Strength coefficient:
a0 : Initial strain
a1 : Strain constant
n : Work hardening exponent
b0 : Initial strain
b1 : Strain rate constant
m : Strain rate sensitivity
As in IV.3.4.1 Flow stress equation, if you have some experimental data such as UTS (Ultimate tensile stress),
Yield strength(Y0), the known parameters to the flow stress can be converted.
Fig.IV.3.29 Convert to flow-stress parameter
• Mechanical Properties
Mechanical properties of material can be set as in IV.3.4.2
Fig.IV.3.30 Material properties: Material Database_Seetings
• Delete
Delete the material item from material database.
• Save
Save the new or changed material properties in database.
• Load
Load the material properties as the material condition of this simulation.
IV.3.5. Roll properties
In Roll Properties, the velocity condition and the physical properties of roll can be defined.
Fig.IV.3.31 Roll properties menu
Fig.IV.3.32 Roll properties
• General
Roll ID : number of roll.
If you want to solve the ring rolling process with SHAPE-RR, you should take care of the sequence of roll id
number. But if you want to solve the spinning process, you don’t need to be careful about numbering of the roll id.
Table 3. Sequence of roll id number in ring rolling simulation
Roll Type Number

Main Roll 1
Pressure Roll 2
Side Roll 3
Side Roll 4
Click the Set button for changing roll ID. Then following window appears. Type the Roll ID and press OK.
Fig.IV.3.33 Change Roll ID
Deformation region ID : number of deformation region.
Rolls that are set in same deformation part of ring have the same deformation region ID.
Fig.IV.3.34 Change Deformation Region ID
Value Roll property
0 Clamping roll
Deformation region id
1,2,3… Driving roll, Idle roll
• Movement control in Roll Property
1. Time, Stroke, or workpiece outer diameter VS Velocity

Generally the pressure(mandrel) roll moves to Y direction. The roll velocity can change according to (see
Fig.IV.3.35 a)) following units ;
1. Time
2. Stroke
3. Designated workpiece outer diameter
Then you can define changing movement condition as well as constant value(see Fig.IV.3.35 a)). The value of roll
movement is generally velocity.
Fig.IV.3.35 a) Roll movement control – various movement

You can change the movement values by click the add/delete/modify button. (see Fig.IV.3.35 b) )
Fig.IV.3.35 b) Movement condition with Velocity

2. Time,Stroke, or workpiece outer diameter VS Force
when the rollis the clamping roll (Deformation region ID is 0) on Z direction, the force is also available. (see
Fig.IV.3.36 a) )
Fig.IV.3.36 a) Roll movement control(2)
You can change the clamping force by click the add/delete/modify button. (see Fig.IV.3.36 b))
Fig.IV.3.36 b) Movement condition with Clamping Force
• Adjust roll to workpiece before starting analysis:
This function is to move the roll to workpiece when roll and workpiece have no contact area. You had better check
this function to save the calculating time.(see Fig.IV.3.36 c) )
Fig.IV.3.36 c) Adjustcent option bet. workpiece and roll
* Check: When roll is adjacent to workpiece, analysis is started.

* Uncheck: No matter roll is adjacent to workpiece or not, analysis is started.
• Physical Properties
* Friction Factor(m) of roller : Friction between roll and workpiece. (0<m<1)
τ k
Frictin factor can be defined rate between shear strength( i )of contact area and shear yield stress( ). If m is
zero, there is no friction. If m is 1.0, it is sticking condition.
τi
m=
k
* Roll temperature(Celsius) : Initial roll temperature (when thermal analysis)
IV.3.6. Simulation environments
Simulation environments is to define the simulation conditions and roll properties and material properties.
Fig.IV.3.37 Simulation environments menu
IV.3.6.1. Process conditions
Process Condition is for determining simulation environment and process condition. Also, unit is determined in the
process condition.
Fig.IV.3.38 Process conditions
• Step Condition:
i) Stroke increment
Fig.IV.3.39 Process conditions according to Stroke increment
Define the stroke value roughly per step.
9 Allowable stroke per step :
This value may be different value from
simulation
Total stroke of driving roll
9 Total stroke
Step interval of simulation
9 Step frequency saving result
You’d better set this value 1/1000 of
9 Initial stroke
allowable stroke
9 Allowable tolerance fator

between node and roll(die)
ii) Time increment
Fig.IV.3.40 Process conditions according to Time increment
Define the stroke value roughly per step.

9 Allowable stroke per step :
This value may be different value from
simulation
Total time of process
9 Total time :
Step interval of simulation
9 Step frequency saving result :
You’d better set this value 1/1000 of
9 Initial stroke :
allowable stroke
9 Allowable tolerance fator

between node and roll(die) :
IV.3.6.2. Remesh option

Remesh option is to use auto-remeshing during the simulation. The remeshing will be executed if following
conditions go over even one criterion.
Fig.IV.3.41 Remesh option
At first, check the “Use Remeshing” button

• Maximum step increments:
Each step increments the remeshing will be executed.
• Minimum elemental angle:
If any acute angle falls under minimum elemental angle for two dimensional mesh of all radial section, the
remeshing will be executed.
Fig.IV.3.42 Mininum elemental angle
IV.3.6.3. Numerical analysis conditions
This numerical analysis options are only for advanced user who are used SHAPE-RR. So, It is proposed to use
default value.
Fig.IV.3.43 Numerical analysis condition
Tolerance error limit for During the Newton-Raphson iteration process, it is assumed that the
fractional norm (RTOL) solution has converged if the fractinal norm is less than RTOL.
RTOL=10-4-10-5 is desirable.
Tolerance error limit for During the Newton-Raphson iteration process, it is assumed that the
functional norm solution has converged if the fuctional norm is less than FLIMIT.
(FLIMIT) FLIMIT=10-2-10-3 times of initial yield stress is desirable. If the
solution error is within both ROTL and FLIMIT, then the solution is
regarded as completely converged one.
Penalty constant to Penalty constant DIAT should be a larger positive number. DIAT=105-
enforce volume 106 is desirable.
constancy (DIAT)
Starting value of Starting value of deceleration to improve the convergency of solution

deceleration to improve by the Newton-Raphson iterative method. When the solution is well
the convergency of behaving, deceleration coefficient is set to 1(unity), But it is frequently
solution (ACOEF) necessary to start the deceleration coefficient with small value. e.g.,
0.1-0.2 (For more detail about iterative methods and deceleration
coefficient)
Limiting value of Limiting value of effective strain rate within which the material is
effective strain rate considered to be rigid. ALPH=0.001 is desirable for the normal range
(ALPH) of ring rolling processes
Approximate average VPCT is used only when the initial guess is generated for the first time
strain rate (VPCT) by direct iterative method. VPCT=0.01-0.1 is desirable for the normal
range of ring rolling processes.
IV.3.7. Project location
Project location is for saving output files of simulation.
Fig.IV.3.44 Project Location menu
Type the project name and folder name which you want. Then automatically folder is made in the given
directory.
Fig.IV.3.43 Setting project location
Note) There is no use to make directory to save output files. After naming Project folder, named folder is
automatically made.
V. Solution Phase
V.1. Starting the simulation
To start the finite element simulation, it is necessary to ready to solve. The solver reads “xx.rri” file that is created
SHAPE-RR after proper pre-processing or started with RRI file. All the data in “xx.rri” are legal, then the solver is
ready to start.
Fig.V.1.1. Solution menu
Note) If Start/Resume is not highlighted or not ready for activation yet, you can't use it. To use this command, please
follow up the proper procedures described in the previous chapters.
Fig.V.1.2. Ready to solve
To start up the solver, push Start/Resume from Solution menu. If the input data is valid, you can see the message
from Output bar as shown below figure.
63 V. Solutions
Fig.V.1.3. Output message
You can monitor the simulation status by activating the output bar. During and after the simulation, you can
investigate the simulation results by using the post-processor of SHAPE-RR.
When the solver is starting to run, the Windows OS becomes very busy to assign memories and to allocate temporary
files into somewhere in your hard disk drive. This work lasts for a minute. Therefore, you will feel suddenly that
SHAPE-RR is very slow and some functions do not work well. But, this is normal. The Windows OS is too busy to
handle with SHAPE-RR. If you avoid this occupation of system resource, change Task Priority. It is to control the
order of priority to resource. Highest means that the SHAPE-RR is the most prior than others in the processor of
system. So you can control the order of priority to use the system harmoniously with other applications.
Fig.V.1.4. Task priority
64 V. Solutions
V.2. Controlling the solver
While solving the project, you can stop simulation and pause simulation momentarily from Solution tool bar. Also
you can change the order of task-priority.
Fig.V.2.1. Solution tool bar
Solver management icons offer this function.
Table.1. Solver management icons
Tool bar Command Description
Start Start SHAPE-RR Solver
Pause Pause SHAPE-RR Solver
Stop Stop SHAPE-RR Solver
Tasks Priority Control the speed of SHAPE-RR Solver
65 V. Solutions
V.3. Restarting from the existing file
From time to time, it is necessary to restart the current design from a specific step with a slightly different
(modified) design, not from the beginning. Is it possible? Yes, if you only have the necessary files up to the specific
step, which means you already simulated the design once in a while and you know the location of the files.
Open RSF file from Project location folder.
Fig.V.3.1.(a) Open RSF format file.
Click Restarting Strategy button to restart.
Fig.V.3.1.(b) Pre-Process menu
If simulation step is finished until 3 step, user can start the simulation between 2 step and 4 step. In this window
users can change directory where user want to save. Select step where user want to start. Then click OK to restart.
Fig.V.3.2. Restarting Option menu
66 V. Solutions
V.4. Restart with modified environments
You can restart with modified environments. The below items can be modifiable.
• Roll geometry
• Movement condition of roll
• Section mesh
• Radial section properties
• Simulation environments
V.4.1. Preparation
The procedure for setting up restarting is same as the case of previous chapter.
Fig.V.4.1 Restart Strategy dialog box
If the setting of restarting is completed, then you can change each items.
67 V. Solutions
V.4.2. Change of roll
If you want to change the roll, you must erase the exist roll to be changed, and import the new roll.
Fig.V.4.2. Deleting a axle
Fig.V.4.3. Import menu
The below figure shows that the new main(forming) roll is being imported to SHAPE-RR.
Fig.V.4.4. Importing Geometry dialog box
Fig.V.4.5. New roll
68 V. Solutions
Where, if the new roll is imported, you must define the roll properties.
Fig.V.4.6. Roll properties

V.4.3. Change of section mesh
SHAPE-RR supports re-meshing as the simulation restarts. The sectional outline of the SMS solution will be initial
section profile. With this profile, you can make re-meshing by means of two methods.
V.4.3.1. Using the auto mesh generation
The procedure of using the auto mesh generator is same as mentioned chapter III. You do sampling the outline of
section profile in Initial section profile from Preprocess menu.
Fig.V.4.7. Sampling for outline
Next, assign the density to sampling.
Fig.V.4.8. Sampling condition
69 V. Solutions
As the mesh is made different by the number of minimum length, you should try the meshing until getting good
meshed section.
Fig.V.4.9. Meshed section
V.4.3.2. Using the mesh data
You can import the mesh data as the mesh of initial section. But only UNV(Universal, not it of SHAPE-RR) file
is available. It is noted that the section profile used in outer mesh generator must be same as the sectional outline of
workpiece.
When you make a drawing in outer mesh generator you should work on X-Y plane. Although the initial section of
SHAPE-RR is on Y-Z plane, you need not to consider its transformation. The SHAPE-RR will transform X-Y plane
to Y-Z plane.
Fig.V.4.10. Sectional shape of workpiece
The SHAPE-RR supports the exporting geometry. You can export the geometry to DXF file and IGES file. As using
this function, you can export the sectional shape of workpiece correctly.
For example, if you want to generator a mesh as using IDEAS, you have to export the sectional outline of
workpiece to IGES formatted file.
Fig.V.4.11. Preprocess menu
70 V. Solutions
Fig.V.4.12. Exporting geometry
To import the exported IGES file in the IDEAS, you must start with Design application.
Application Design
Task Master Modeler
Fig.V.4.13. Importing to IDEAS
The below figure shows the IDEAS imported the section profile successfully.
Fig.V.4.14. Imported section to IDEAS
Then you do mesh the imported section with the IDEAS
Fig.V.4.15. Meshed section in IDEAS
71 V. Solutions
After the meshing, you can export the mesh data to UNV(Universal) file.
Fig.V.4.16. Exporting mesh data
Then you have to try import the UNV file to the SHAPE-RR.
Fig.V.4.17. Importing mesh data
It can be accomplished as Import Geometry command from Preprocess menu.
Fig.V.4.18. Selecting file
If the importing is executed successfully, you can see the meshed section as a below figure.
Fig.V.4.19. Imported mesh data
V.4.4. Change of radial section property
You can change the radial section properties as restarting. The method of setting for radial section properties is
same as mentioned chapter V.3.
72 V. Solutions
Fig.V.4.20. Radial section properties
After changing the radial section properties, you can verify the spatial meshed solid as you set the properties of
SMS.
Fig.V.4.21. Pre-estimated SMS
V.4.5. Change of simulation environment
Also you can change the process conditions and the numeric analysis options in the Simulation environments.
Fig.V.4.22. Simulation environments
73 V. Solutions
After that, you can restart with modified environments.
Fig.V.4.23. Solve menu
74 V. Solutions
VI. Post processing phase
This Chapter is for ‘Post processing phase’ to examine the results of analysis. Results of analysis can be shown
such as, distribution of ‘Effective strain’, ‘Strain rate’ and ‘Longitudinal strain’ etc… and by using the GUI of
SHAPE-RR the curve of the results can be created variably.
VI.1. Files for post-processing
You can open project-name.RSF file for the post-processing. The file with extension RSF, may include a lot of
results of steps.
The UNV or RRS, TAPE file is not generated by the solver any more. But the new version still accepts those files.
VI.1.1. RSF File
The RSF file has a lot of results for number of steps. If you open the RSF file, the Out-put file open dialog box
will be shown as Fig.VI.1.5. You can see the list of steps that is included in RSF file. Then you can select files
you want to open. You can also select the mesh-system to be opened.
Fig.VI.1.1 Opening out-put files
VI.1.2. Importing RSF File
After opening RSF file, if you want to append other steps to current project, use the Import from the File menu.
Fig.VI.1.2 Import RRS
For examples, If you want to append results of two steps, select same RSF file.
And select two steps with same mesh system.
75 VI. Post-processing
Fig.VI.1.3 Select steps
Then the results of two steps will be appended to current project as shown Fig.VI.1.4.
Fig.VI.1.4 Appended RRS files
VI.2. Issues of The Analysis
While SHAPE-RR is solving, SHAPE-RR produces two solution files which is result by each mesh-systems,
respectively AMS, SMS. Each mesh-systems show different result like below.
VI.2.1. Result from AMS
• Total effective strain

• Freudenthal
• Cookcroft-Latham
VI.2.2. Result from SMS
• Total effective strain

• Effective strain rate
• Pressure
• Contact node
• Vx
• Vy
• Vz
• Vθ
• Vr
VI.3. Verification of Result
VI.3.1. Nodal solution
The various result of each mesh-systems can be verified by Contour window. The default issue is the total
effective strain as shown Fig. If you want to change issue, select other issue in combo-box.
Fig.VI.3.1 Total effective strain on AMS
For examples, If you want to change issue to Freudenthal, select Freudenthal in combo-box as shown below
figure.
Fig.VI.3.2 Information bar
Then the contour of workpiece will be change like below figure.
Fig.VI.3.3 Freudenthal on AMS
The contact node of workpiece on SMS is shown as the following figure.
Fig.VI.3.4 Contact node on SMS
VI.3.2. Creating sliced workpiece
Open *.RSF file format
If you don’t know section number you want to see,
Click the Filter icon and Select Polygons&Elements and Solid Section.
Set Selection filter
Click the Wireframe icon , you can see the workpiece as wireframe.
Then move the mouse close to the cross section you want to see, the selected cross section will be high light.
You can see section number (red box) at property bar
highlighted cross section
Select Post process -> Create Sliced Workpiece
Insert the cross section number at Starting section and Ending section.
(Ending section number is always bigger than Starting section number.)
Fig.VI.3.5 Create Sliced Workpiece
You can see the cross section you want to see.
Fig.VI.3.6 Sliced workpiece
VI.3.3. Creating flow-net
For initial setting of flow net, click Post Process -> Flow net (see Fig.VI.3.7)
Fig.VI.3.7 Settings of flow-net, Step1[Primary Layer]
At the result of SMS or AMS, you can verify the flow-net. The initial net can be rectangular form. You can
specify the start and end step and the density of initial net form. Each parameter, number of horizontal and
vertical divisions, can't exceed 100(see Fig.VI.3.8).
Fig.VI.3.8 Settings of flow-net Step2[Primary Layer]
In order to see the flow-net, change the layer to Flow-net layer(Fig.VI.3.9), and then you can see Initial netted
section.(see Fig.VI.3.10)
Fig.VI.3.9 Flow-net layer [Flow net Layer]
Fig.VI.3.10 Initial netted section[Flow net Layer]
VI.3.4. Animation
The workpiece and flow-net is supported the animation that the step is updated to next in regular order. You can
change the refresh speed which is milli-second.
Fig.VI.3.11 Setting of refresh speed
If you click Start from Animation menu, the animation will be started. Also you can pause and stop the animation,
and ESC key will work as stopping the animation.
Fig.VI.3.12 Starting menu of animation
VI.4. Making a rendered results
VI.4.1. Changing Contour Mode

SHAPE-RR supports various contour styles - shade, filled polygon, filled element and line strip mode. You can
verify results with it.
To change the contour mode, select proper contour style in Contour from Post-process menu.
Fig.VI.4.1. Contour styles
The description of each contour style icons is shown in Table.VI.4.1. And Fig.VI.4.2~6 show features applied
contour styles respectively.
Table.VI.4.1. Description of contour styles
Too
Comma
l Description
nd
bar
Shaded The calculating results will be
Contour in transit homogeneously
Filled The results will be displayed
Polygon in filled polygon
The results will be seen in
Line
contour lines, which
Strip
interpolate the node values.
Filled The simulation results will be
Element seen in a element
Hide The sheet will be seen in hide
Contour contour
Contour
Changing pattern of contour
Properti
properties
es
Fig.VI.4.2. Shade mode
Fig.VI.4.3. Filled polygon mode
Fig.VI.4.4. Filled element mode
Fig.VI.4.5. Line strip mode
Fig.VI.4.6. None mode
VI.4.2. Changing Contour Properties
The contour properties can be changed to your preference. To change the properties, click the Contour
Properties. In this dialog box, you can modify levels of contour and define colors of contour levels.
VI.4.2.1. Contour Levels
You can change levels of contour and other properties. It is noted that the large contour levels will consume the
system resource for rendering features. So you should select the number of contour levels properly.
Fig.VI.4.7 Contour Levels in Contour Properties
• Number of contour levels(2-50) :

The displaying color will be in transition from the max. value to min. value by the number of contour levels in the part.
• Regular Interval
The values between the max. value and min. value will be divided by equal length.
• Restore Bounds
Resetting the max. value and min value as default value.
• Exponent notation
If the blank is checked, the value will be expressed in exponent.
• Show positive sign
If it is checked, the value will be assign by plus or minus.
• Position of the decimal point
If the blank is filled in 2, the number of value before exponent is two.
• Position of the multiplier
If the blank is filled in 3, the number of power is three.
For examples, on Filled Polygon mode, if you change the number of contour levels to 30, from 8, the contour
will be changed as shown below figures.
Fig.VI.4.8 Contour levels 8
Fig.VI.4.9 Contour levels 30
VI.4.2.2. Color Palettes
You can change type of contour color and define each color of contour levels.
Fig.VI.4.10 Color Palettes in Contour Properties
• Type
Setting the type of contour palette
(There are “Custom”, “grayscale”, “RGB”, “MBYR” and “YRB” type in the combo-box)
• Contour Preview
Previewing bar of current contour
• Palette List
Select a color
• Insert after
Inserting the user color after the currently highlighted color.
• Modify
Modifying the currently highlighted color.
VI.5. Plotting Curve From Simulation Results
SHAPE-RR supports the plotting curve from simulation results. You can verify and compare the results by graph.
VI.5.1. Tools For Plotting A Curve
Fig.VI.5.1 Tools & Filters
Table.VI.5.1. Description of Tools & Filters
Tool
Command Description
bar
Change
picking mode Change picking mode
to entity to entity selection
selection
Change
picking mode Change picking mode
to object to object selection
selection
Circular Select the points along
selection the circular direction
Create group for
Create group
current selection
Create curve Create curve data from
from group selecting group
Curve Display curve
plotting properties in graph
VI.5.2. Curve Plotting In Detail
If you want to select object(s) that you need, click the Filter icon. Then, the Filtering window appears as below
Fig.VI.5.2(a) Before Selecting Fig.VI.5.2(b) After Selecting
Select the object that you want to select in Object List and click the icon. Selected object moves from
“Object List to Selectable. If you want to select all objects in Object List, click the icon. (No need to
select any object in Object List). The selection of object(s) can be deselected by clicking the icon or
icon.
VI.5.2.1. Create Group
To create the nodes group, you must select nodes. There are two methods selecting nodes. One is to select nodes
you want. The other is to use the function that selects all circular nodes for picked only one node. To use the latter
case, click Circular Selection.
Note) Enter Esc key to cancel the command and press Shift and pick the one node on the other pass for
continuous select.
Fig.VI.5.3 Selected nodes with Circular Selection command
To create group click the Create group from Post-process as presented in Fig.VI.5.4
Fig.VI.5.4 Post-Process menus
Then the Create Group window will appear as presented in Fig. VI.5.5. If you want to rename the group, you
write down the name in the text box and then click the Create command button.
Fig.VI.5.5 Create Group window
VI.5.2.2. Create Curve from Group
To create curve for group, click the Create Curve from Post-process menu. Then Group/Curve Manager
dialog box will appear as shown in Fig.VI.5.6.
Note) If there is no groups have been created, this icon is not active.
Fig.VI.5.6 Group/Curve Manager
• Group:
There are group-names and its type(s) you have created in this part of window.
• X-axis and Y-axis:
You can select the X-axis and Y-axis of the curve
• Curve preview:
The curve is shown whenever you select the X-axis and Y-axis
• Remove Grp., Add Curve and Remove Crv. Command button :
You can remove the existing groups, add the curve and remove the existing curves by using this command buttons
• Curve List: The created curve is shown in this part of windows
Then Select the X-axis and Y-axis data as presented Fig.VI.5.6 and check the curvet. After that, click the Add
Curve command button.
A Create New Curve window will appear as presented in Fig. VI.5.7.
Fig.VI.5.7 Create New Curve
Where, if you want to rename the curve title, you can write down the title in text-box in the Create New Curve
window and then click the Create command button.
VI.5.2.3. Curve plotting
If you have created curves from the group you selected, you can verify and compare curves by Curve Plotting
from Post-process menu.
Click Curve Plotting, then Curve Plotting window will appear as presented in Fig.VI.5.8.
Fig.VI.5.8 Curve Plotting
You can compare the curves as selecting several curves as shown in Fig.VI.5.9.
Fig.VI.5.9 Comparison of curves
VI.5.2.4. Using Tool bar in Curve Plotting window
Curve Plotting has the tool-bar. With tool-bar, you can manipulate the curve and verify the result with various
functions.
Fig.VI.5.10 Toolbar in Curve Plotting
Table.VI.5.2. Description of Curve Plotting toolbar
Tool
Command Description
bar
Open chart Open an existing chart
Save chart Save current chart
Copy to Copying to clipboard as a

bitmap, metafile, text(data only)
Clipboard
and OLE object
Gallery Selecting the type of curve such
as “Line”, “Area” and
“Step” ,etc…
Color Select a color
Vertical grid Grid across the vertical direction
Horizontal grid Grid across the horizontal

dirction
Legend box Legend box
Data editor You can show the data by

clicking this icon
Properties Change the properties of curve
3D/2D Switching the 2D and 3D curve
Rotate If you select 3D curve, you can

rotate the curve.
Z-Clustered Display series in different rows
along the z-axis
Zoom Zooming window
Print preview Print preview
Print Print current graph
Tools Tools which can used
VI.6. Report Generation
SHAPE-RR supports the generation of report. The whole information of simulation is exported to the file which
is formatted HTML currently. The report can be also generated while pre-processing. In this case, only the pre-
processing data will be exported.
Fig.VI.6.1 Tool menu
To generate the report, run Report Manager by clicking Report generate from the Tool menu. Then you can see
the below figure.
Fig.VI.6.2 Report Manager
• Project info:
Project title, Assignment, Executant, Date for simulation
• Project summary: Not available
• Workpiece info:
Ring geometry, Information of sectional mesh and boundary condition
• Roll geometry:
Sectional profile of roll, Velocity condition of roll
• Material properties:
Flow stress equation, Material properties
• Process conditions:
Process condition of simulation
• Analysis conditions:
Stopping criteria of simulation
• Result of solving:
Information of start and end step
• Additional comment:
Referred comment
• Software Info:
Version information of SHAPE-RR
The Additional comment is user's referred comment. You can write the comment by clicking Write button as
shown in below figure.
Fig.VI.6.3 Comment
Fig shows that the generated report is opened by internet browser.
Fig.VI.6.4 Report with internet browser Customizing Features
It is possible to change rendering option and surface refinement. Customized style option changes only physical
appearance, not result.
Fig.VI.7.1 Feature menu
VI.6.1. Rendering options
VI.6.1.1. Appearance
The color of main window and each object can be changed using packaged color set or selecting the color of
each objects.
• Using packaged color sets
Fig.VI.7.2 Selecting the color set
Select the black set in the color scheme, and click the Apply. The main window and all objects colors will be
changed under the pre-defined color set as showing Fig.VI.7.3
Fig.VI.7.3 Changing the color set to black set
• Changing the color of each item
Select the item in the combo box, and select the color.
Fig.VI.7.4 Selecting object
Fig.VI.7.5 Standard colors
Fig.VI.7.6 Other colors
Fig.VI.7.7 Changing color of roll skin
VI.6.1.2. Light properties
If the Light option in Render from Feature menu is used, the appearance of object is recognized exactly. The
light position can be changed by the input of position coordinates.
Fig.VI.7.8 Render toolbar
Fig.VI.7.9 Change of the light position

• Light position
The coordinate of light position is independent to object coordinates. It is only determined to screen coordinates
as shown Fig.VI.7.9.
If the coordinates of light position have only Z-axis value, the light source is located at front (or back) as shown
Fig.VI.7.11. The Fig.VI.7.12 shows the case of light position (0, 10000, 0).
x
z
Fig.VI.7.10 The coordinate system of light position
Fig.VI.7.11 Light position (0, 0, 10000) Fig.VI.7.12 Light position (0, 10000, 0)
• Degree of shininess
It is to control the shininess of the light. If the degree of shininess is increased then the light is concentrated upon
the normal plane of the object.

VI.6.2. Surface refinement
The feature of roll geometry is depicted by the synthesis of segments of straight line or plane. The large amount
of segments is required the expensive computational resource to render the feature. To avoid high-priced
rendering, it is recommended that the number of segments should be given properly.
Fig.VI.7.14 Surface refinement
Note) This option is available for only displaying the roll in the window.
VI.6.2.1. Arc depiction
L
θ
Fig.VI.7.15 The segment of arc depiction
• Maximum length(L) of dividing segments

It determines the maximum length to divide the arc.
• Minimum angle(θ ) of dividing segments
It determines the minimum angle to divide the arc.

VI.6.2.2. Revolution
The number of subdivisions along the roll axis
It determine the number of divisions along the roll axis to revolute the roll description.
Fig.VI.7.16(a) The case of 15 divisions (b) The case of 60 divisions

VI.7. Image Capture
VI.7.1. Specification of region to be exported
To capture the image on screen, click Capture from Tool menu. You can see Screen Capture dialog box.
Fig.VI.8.1 Tool menu
Click Start drag to specify the region which is to make export.
Fig.VI.8.2 Screen Capture
In the screen, if you push down the left button of mouse, the region will be specified with a rectangular mark
until you push up the left button of mouse as shown in Fig.VI.8.3.
Fig.VI.8.3 Specification of region
If the region is specified, then Screen Capture dialog box will appear with a picture of specified region
automatically as shown in below figure.

Fig.VI.8.4 Preview of captured image
To export the image to file, click ‘Save’ button in Screen Capture dialog box. Then you can see Save As dialog
box. Currently you can export to the file which is bitmap image type. Click Save button after you define the name
of image.
Fig.VI.8.5 Save As window
VI.7.2. Full Screen Capture
To capture the whole screen, click Full image button in Screen Capture dialog box. For examples, as the screen
of SHAPE-RR is like Fig.VI.8.6, if you click Full image then the whole screen will be shown in Preview as
shown Fig.VI.8.7. To save in file, click ‘Save’ button.
Fig.VI.8.6 Main window
Fig.VI.8.7 Preview of full image

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SHAPE-RR

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I.2. Introduction of SHAPE-RR

I.3. About This Manual

II. Basic Theory

II.1. Velocity Field

II.2. Mesh System

( Actual Mesh System ) ( Spacial Mesh System )

Fig.II.1 Mesh system

1 II. Basic Theory

II.3. Rigid Plastic Finite Element Method

II.3.1. Domain of workpiece

II.3.2. Boundary conditions

Fig.II.2 Boundary condition

2 II. Basic Theory

II.3.3. Governing equations

(i) Equilibrium equations

(ii) Boundary conditions

(iii) Flow-rule (constitutive equations)

(iv) Relationship of strain rate-velocity (compatibility equation)

(vi) Flow stress

3 II. Basic Theory

III. Overview of SHAPE-RR

III.1. Simulation Procedure

III.1.1. Assuming contact

III.1.2. Updating the AMS

Fig.III.1 Updating AMS

4 III. Overview of SHAPE-RR

III.1.3. Updating the SMS

Fig.III.2 Flow chart

5 III. Overview of SHAPE-RR

III.1.4. Updating the ring center

Step1: Updating ring center by velocity field

Step2: Adjusting ring center by the volume constancy

Step3: Locating the geometry

III.1.5. Updating the rotating axles

6 III. Overview of SHAPE-RR

III.2. Overview of SHAPE-RR Windows

Main Display Window: Workspace

Output bar: The message from the solver

Fig.III.3 SHAPE-RR Windows

7 III. Overview of SHAPE-RR

III.3. Setting Preference

Fig.III.4 Preference menu

8 III. Overview of SHAPE-RR

Basic offers several settings for SHAPE-RR.

• Z(depth)-buffer: This option enable to express rich color.

• Enable double-buffer: This option increases analysis speed.

• Accelerated by a device driver: This option offers VGA acceleration.

Fig.III.5 Basic tab

9 III. Overview of SHAPE-RR

Fig.III.5 Directories tab

10 III. Overview of SHAPE-RR

III.3.3. Windows style

Fig.III.6 Windows Styles tab

Fig.III.7 Changing color

11 III. Overview of SHAPE-RR

III.3.4. Hardware summary

Fig.III.8 Hardware Summary tab

Note) In this preference menu, default values are recommended.

12 III. Overview of SHAPE-RR

III.4. Using The Mouse to Control Object

Table 1 Use of "hot keys" and mouse button