Simulating Forming with Simufact.forming

A simulation tool for hands-on forming professionals

Easy-to-use for the highest level of productivity

Simufact.forming is a simulation tool for hands-on professionals working with forming technology. Our goal is to focus the software to the practical needs of the users. Our customers confirm the fact that we have achieved a lot in this field.

The operation of simulation software very often requires a lot of expert knowledge to build up and program complex models. This is not the case with Simufact.forming: The user can focus on the engineering-related details of the forming process. He does not have to deal with the physics of the forming process, nor with simulation-specific details. Simufact.forming is application-oriented as well as easy and fast to master.

Simufact.forming’s standard user interface allows for the software to be easily used and therefore, to become an engineering tool for developers of dies or processes whose daily work is supported and simplified. With a few clicks, all standard-forming processes can be simulated and evaluated.

Simufact.forming stands out due to its easy-to-use design and the fact that it only takes a short time to become familiar with it. The most significant advantages of the hands-on and user-optimized graphical user interface (GUI) are:

  • Easy, intuitive Windows style user interface (e.g. drag & drop)
  • Very easy and quick to learn
  • Forming technology terminology
  • Clear structure according to the object area (dies, machines, material etc.), process area (forming operations) and graphic model / results area
  • All objects can be provided by databases
  • AFS technology (application function sets) simplifies use
  • Template technology supports the user during the simulation set-up and conducts process-specific expert adjustments in the background. The user can fully focus on the process to be simulated. Numerical expert knowledge is unnecessary
  • Context-based help system for all user inputs with links to further information and example models
  • All simulation results can be displayed and evaluated graphicallyusing plots, animations and diagrams while a simulation is still running
  • Pre-processing and post-processing are united in one GUI. This reduces the need for training and simplifies the simulation of multi-stage processes
  • Extremely easy to generate model variants.



Simufact.forming Version 13 - now available

Simufact.forming 13

Simufact.forming 13 provides improvements in post processing, evaluation and the depiction of the simulation results, result precision, software stability, and speed. Simufact.forming 13 offers a range of functional enhancements:

What´s new

What do you want to achieve with your process simulation?

  • Ensure feasibility and process stability
  • Develop new products more efficiently
  • Reduce the number of trial runs
  • Document knowledge and expertise
  • Reduce material usage
  • Reduce rework
  • Increase die life
  • Decrease reclamations
  • Market your own achievements and cultivate your image

AFS Technology

With product version 12, Simufact has introduced the newly developed AFS technology (Application Function Sets).

AFS provides specific process-dependent configuration such as the choice of the right solver, the meshing technology, process-specific kinematics and advanced settings. Application-specific functions are activated and the software focuses on the process-relevant functions while hiding those functions specific to other application areas.

The new AFS technology means access to the simulation is more intuitive, faster, and more affective.

Please note that Simufact.forming’s application modules are secured by licenses. We will be happy to advice you on which combination of modules is best to simulate your manufacturing processes. For further information, please refer to our sales contacts.

Realistic Simulation Results

Highly precise results

Simufact.forming takes into account all areas of forming technology and therefore ensures a highly realistic simulation of the processes. We achieve this high degree of precision by using boundary conditions and representations that have been conceived with the demands of the user in mind. Simufact.forming takes into account:

  • The kinematics of the machine, no matter what kind, and no matter how complex
  • The behavior of the material, elasticity, plasticity, hardening and softening, as well as effects that depend on temperature and speed
  • The friction and contact between the tooling and the workpiece
  • The thermodynamics of the process, workpiece heating, heat transfer into the dies and into the environment, temperature increase due to forming energy, friction heat, etc.

 

What the experts say

"Simulation is constantly gaining importance in the forming industry as it can significantly advance our sector in terms of energy efficiency, material saving and lighter components.”

Dr. Theodor L. Tutmann, CEO Industrieverband Massivumformung (IMU)

"As easy as possible – as complex as necessary"

The complexity and precision of the simulation model can be increased, if necessary. For example, single pre-defined model parameters can be replaced by measured values.

A multitude of further functions allows the experienced user to model all conceivable processes, however complex they may be. For experts, user interfaces are provided to enable an adjustment of the calculation algorithms, e.g. for research purposes.

 

Unique Dual Solver Technology

Mature solver technologies, with the highest precision of reproducing the relevant physical effects, contribute substantially to the high quality of Simufact.forming’s simulation results.

Simufact.forming offers two numerical calculation methods for the simulation that complement each other:

  • A finite-volume solver, based on MSC´s explicit Dytran solver, is used for the especially efficient simulation of warm and hot forging processes with significant burr formation
  • A finite-elements solver, based on MSC´s implicit Marc solver for nonlinear applications, is used to simulate all process types.

Both solvers have continuously been developed by MSC over the past decades and make it possible to reproduce the complex, nonlinear physics of forming processes with the highest precision. These solver technologies offer the utmost precision in result by the use thermo-mechanical, elasto-plastic element formulation.

Besides the quality of the results, in practice the computation time is another especially relevant quality criteria. Only short computation times make the use of simulation software relevant for daily work. Simufact offers the efficient parallelization of simulation with its additional Performance module: The use of the highly effective methods, domain decomposition method (DDM) for the FE solver and shared memory parallelization (SMP) for FE and FV solvers, allows the computation time to be effectively decreased.

 

Simulation videos

Joining process self-piercing riveting

 

Ring rolling process

 

Functional Description of Simufact.forming

Applications of Simufact.forming

Simufact.forming allows for both two-dimensional (axisymmetric and planar) and three-dimensional simulations on the same graphical user interface. Three-dimensional simulations can use symmetries of the real process (cyclic symmetries as well!) to effectively reduce model size and computation effort. Any kind of transition from two- to three-dimensions, with or without symmetries, is possible.

All temperatures, from room temperature to almost melting point, can be simulated. The simulation always takes into account (even for cold forming processes) dissipation and friction heat, as well as the heat transfer with dies and the environment.

All (metallic) materials common to forming technology can be simulated. The material database shipped with the Simufact.forming Hub already includes:

  • Light metals (aluminum, magnesium, titanium)
  • Steels (carbonaceous, low and highly alloyed, austenitic and dual phase steels)
  • Non-ferrous heavy metals (copper, brass, bronze)
  • Zinc alloys
  • Heavy metals (lead, cadmium, zirconium, uranium)
  • Special alloys (nickel-copper alloys, nickel-chromium alloys and others)
  • Super alloys (Inconel, Hastelloy, Waspaloy, Incoloy, Nimonic)

In addition to this, typical tool steels for the characterization of elastic dies are included, too.

The recrystallization behavior of steel and nickel based alloys can be examined with the module Microstructure Matilda.

All forming machines common to forming technology can be simulated. The user can describe special kinematics in table format. Rotating tools are simulated by the Rolling module. Simufact.forming simulates closed loop controlled aggregates such as those used for ring rolling or open die forging with the respective application modules.

 

Process Chains

Modeling entire process chains

The application module’s functions allow for the simulation of single manufacturing steps. However, the modules can also be combined spanning applications and products in order to connect the various manufacturing steps to entire process chains and to simulate these as a whole:

  • Integrated process chain simulation of any forming technology manufacturing sequence by linking and using arbitrary application modules
  • Integrated process chain simulation of all forming processes and mechanical joining operations (using the Mechanical Joining application module)
  • Process chain simulation by linking forming processes and welding processes together, with the highest result precision based on complete compatibility of solver and material models with Simufact.welding
  • The influence of heat treatments on the forming properties of the material can be simulated globally with Simufact.forming
  • The Heat Treatment application module offers a more detailed look into local material properties during heat treatments
  • Export the simulation results to third-party products, for example for fatigue and crash simulations

Functional Highlights

Functional highlights of Simufact.forming

  • Simufact.forming’s graphic user interface (GUI) is especially designed for metal forming simulations
  • All relevant auxiliary processes, such as pre- and intermediate heating, deburring and cooling processes can be simulated closely related to real life.
  • The GUI offers one single interface both for 2D and for 3D simulations, no matter what the application. Application-dependent GUI elements are contributed by the application modules and are integrated seamlessly into the GUI. This guarantees a short initial training phase
  • Databases store all model components and process properties allowing for the re-use of all previous inputs
  • CAD import from all common formats, import the whole assemblies
  • Automatic correction of faulty CAD geometries by the integrated program CADfix® from our partner ITI TranscenData
  • Meticulously pre-defined boundary conditions and automatisms enable the user to generate a simulation model and to evaluate the results in a short time
  • Comprehensive materials database with data sets for about 750 materials
  • Die stress simulations can either be done directly coupled with forming simulations or, alternatively, they can be done decoupled during post-processing
  • Stage Control for linking multi-stage processes
  • Post-processing particles can be tracked forwards and backwards across any number of forming stages
  • Routine evaluations, for example when examining variants, can automatically be fed into reports
  • Comprehensive data base of examples and tutorials for self-training
  • Flexible license model
  • Efficient remote functions for central workstations and clusters
App. Simufact.forming GUI
Simulation of orbital forming with Simufact.forming – different perspectives on the workpiece
CAD import and positioning
CAD import and positioning
Product Portfoilio Simufact.forming

Modular structure

Simufact.forming has a modular architecture. The modular concept of Simufact’s products helps you to choose the relevant functions for your needs. This approach saves you costs and gives you the flexibility to adapt to changing requirements.

With its application modules, the software line offers process-specific functions for all the relevant application areas of forming simulation. The modules’ functions enable the simulation of single manufacturing steps and can be combined to simulate entire process chains.

Additional modules offer you a whole range of further valuable functions for the daily use of the software.

 

 

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