Simulating Cold Forming

Management Summary

Simufact Forming Cold Forming serves the simulation of bulk forming processes below the recrystallization temperature of the material. The module helps you to prevent common manufacturing errors such as:

  • Lap formation
  • Markings created by shearing edges 
  • Insufficient die filling
  • Cracks
  • Excessive press and die loads

Simufact Forming Cold Forming considers all relevant boundary conditions, including stress rings and spring supported dies. The realistic prediction of the forming forces, while taking into account spring back effects and the elastic-plastic material behavior, is necessary for a high precision simulation of cold forming processes. 

Utilize the advantages of Simufact Forming for your cold forming processes:

  • Reduced testing effort during design and prototyping
  • Shorter development times
  • Optimized stage planning according to press capabilities (Press force distribution of individual stages)
  • Higher process understanding of complex die designs (spring supported dies, flashless precision forging)
  • Optimized die life through investigation of die loads
  • Correct die material selection
  • Optimized design of stress rings
  • Higher process stability and quality

 

Prevent premature tool failure

How can simulation prevent tool failure in conjunction with process monitoring systems?

A consortium from Simufact and Prokos GmbH, the specialist for process monitoring systems in forming technology, and the Möhling GmbH & Co. KG, the expert in the area of cold forming and cold formed components has analyzed this question. Read here the first results of the cooperation.

Read Article

Modeling the Entire Process Chain

The entire process chain of component manufacturing can be simulated using Simufact Forming. Beginning with wire drawing, followed by multistage cold forming processes, and if necessary interstage annealing and final heat treatment. Trimming and piercing operations can also be considered. This allows the prediction of component properties based on local material properties, and their use in situations such as final stress analysis.

 

Article: Impact of Simulations on Cold-Forging Designs

Simulation videos Cold forming

Optimization targets

Optimization Goals

  • Reduce test efforts
  • Shorten development times
  • Optimize process stability
  • Increase die life

Die Analysis

High forming pressures are characteristic of cold forming processes, therefore the component and the dies always have to be considered in process design. For this reason, we recommend to combine the Cold Forming application module with the additional Analysis module. It is our pleasure to advise you on the advantages of this combination. For further information, please contact our sales department.

Materials and Varieties

Simufact Forming Cold Forming considers different materials and varieties

App. Material Steel
Material Steel
  • Plain and low-alloy steels
  • Austenitic steels
  • Aluminum and aluminum alloys
  • Copper and copper alloys (brass)
  • Titanium

Functional Highlights

Utilize the functional advantages of Simufact Forming Cold Forming

  • Simufact Forming Cold Forming assists in the design of stage plans
    • Testing of innovative ideas
    • Virtual comparison of alternative designs
  • Simulation model builds on the dies’ CAD data
    • Standard formats: STEP or IGES
    • Import filter for all common CAD-Formats available 
    • Intelligent automatic discretization of CAD data
    • 2D DXF data can be used
  • All modeling in 3D
  • Provides thorough information about die loads and prestresses in assembled dies
    • Particularly effective with the additional module Simufact.forming Die Analysis for uncoupled die stress analysis
  • Spring supported dies (for both fixed and moving dies) can easily be considered in the module
  • Easy transition between 2D -> 3D and rigid and deformable
    • Thus, the model complexity can be increased gradually
  • Seamless calculation of forming sequences with automatic result transfer
  • Easy modeling of piercing and trimming operations
App. Reinforced die simulated with Simufact Forming
Reinforced die simulated with Simufact Forming
  • Easy exchange of individual die variants
    • Minimal modeling effort for variant calculation
  • Flashless precision forging dies / clamping force prediction
  • Consideration of press deflection
  • Display of press force evolution and evaluation of press force distribution
  • Automatic report generation to evaluate variant calculations
  • Elastic-plastic thermo-mechanic material model
    • Consideration of all physically relevant effects
    • Information about springback and residual stress
  • Subsequent use of simulation results in bracing investigations / assembly calculation (mechanical or thermal joining)
    • Virtual tests on assemblies
  • Material database with datasets for commonly used component and die materials 
  • Easy set-up of customer-specific material data sets
  • Template models and central management of customer specific data sets for presses, friction, etc.
  • Models for damage and die wear
app. Simulation and real display of a spring supported die
Simulation and real display of a spring supported die

References Cold Forming

A large number of users, including leading machine manufacturers, trust in simulation technology from Simufact. Among the users of Simufact Forming Cold Forming are:

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