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

Forming sequence in cold bulk forming (Source: Ejot)
Stages of cold forming – Simulation

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.

Cold Forming
Heat Treatment

Article: Impact of Simulations on Cold-Forging Designs

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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

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

References

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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