This example demonstrates the implementation of VARDAN tool wear model.

VARDAN Tool Wear Model :
WEAR RATE = (((Sliding velocity)^A*(Die temperature)^B*(Interface Pressure)^C)/10000)

WEAR DEPTH = WEAR DEPTH + (WEAR RATE * Time Increment)

A,B and G are exponents of Sliding velocity, Die temperature at interface and interface pressure respectively, which varies with the material. The values of A,B and G are read from GUI into routine using the Code:

CHARACTER*80 IUSRVL
COMMON /IUSR/ IUSRVL(10)

READ(IUSRVL(1),*)A,B,G


The model is apllied for Extrusion operation.

The usr_wear.f file contains user routine implemented in roitune 1

C---+----+----+----+----+----+----+----+----+----+----+----+----+----+--
C
      SUBROUTINE UWEAR1(VMC1,VMC2,VMC3,VMC4,VMC5,VMC6,DTMAXC,WI,WA)
C
C---+----+----+----+----+----+----+----+----+----+----+----+----+----+--
C
      IMPLICIT DOUBLE PRECISION (A-H,O-Z), INTEGER (I-N)
C
      CHARACTER*80 IUSRVL
      COMMON /IUSR/ IUSRVL(10)
C    INPUT :
c        VMC1          ! die temperature
c        VMC2          ! w/p temperature
c        VMC3          ! sliding velocity
c        VMC4          ! pressure
c        VMC5          ! shear stress
c        VMC6          ! nodal area
c        DTMAXC        ! time step
c        WI=WEAR(4,N)  ! wear rate at the previous step
c        WA=WEAR(5,N)  ! accumulated wear depth upto the previous step
C    OUTPUT :
c        WI=WEAR(4,N)  ! wear rate at the end of current step
c        WA=WEAR(5,N)  ! accumulated wear depth upto the end of current step
C
          READ(IUSRVL(1),*)A,B,G
         W=(((VMC3**A)*(VMC1**B)*(VMC4**G))/10000)
         WA=WA+(W*DTMAXC)
         WI=W
         RETURN
         END
C---+----+----+----+----+----+----+----+----+----+----+----+----+----+--

Executing the User routine:

Open the pre-processor and import Extrusion_die_Wear_SI.KEY file from 2D_Examples folder.

Go to Inter-Object properties tab and edit Bottom die and Workpiece relation. Select Tool wear model as "User Define 1" for user routine 1.

Go to Simulation controls > Advanced > user Defined tab. For this example we will be using exponents A,B and G as 1,0.02 and 1, so in first row enter these values as 1,0.02,1

Save the Key file and Generate DB.

Make a copy of the release folder …\2D\UserRoutine\DEF_SIM (and usr_wear.f modified as indicated above)

Open the FORTRAN Absoft 11 and open the DEFORM 2d user routine DEF_SIM_USR_Absoftv110.atools file from this copied location, 
and build local FEM engine DEF_SIM.EXE

Two ways to run this model using the user defined wear model 
1. 
Build the executing files and paste the generated DEF_SIM.EXE in "..\2D\" folder. (first backup release version of DEF_SIM.EXE)
Run the simulation and observe tool wear parameters in post processor after the completion of simulation.
2. 
create a file DEF_SIM_DIR.DAT with first line indicating the path to the folder holding this newly build DEF_SIM.EXE
Run the simulation and observe tool wear parameters in post processor after the completion of simulation.

