The application module Hot Forging brings special functionalities for the simulation of Hot Forging Processes and enables also the process of Hot Die Forging as well as further core processes like Clamping and Cooling, Cutting, prior deformation and also extrusion processes.
Nowadays the simulation of hot die forging is an integral part of a modern CAE environment.
Simufact Forming combines easy and intuitive usability with a reliable prediction of forging processes. The simulation results are useful for advanced product and process development, for the continuous optimization of series processes, and feasibility studies during program bidding.
Simufact customers report sustainable savings and competitive advantages such as:
Reduced development costs through fewer development loops
Reduced trial costs (Production Part Approval Process ‘PPAP’ or Prototyping, pilot series)
Increase of new business due to shorter time-to-market performance (get faster ‘Start of Production’ (SOP))
Declining fixed costs through higher machine utilization
Lower quality control costs via higher process stability and quality
Lower manufacturing costs through improved material yield (reduction of forging flash and excess material)
Reduced manufacturing costs due to fewer process stages
Less scrap and lower rework costs
Lower tool cost through increased tool life
Reduced energy costs through better efficiencies of individual process steps
Prediction of component properties
Modeling of entire process chains
Simufact Forming enables modelling of entire process chains in hot forging beginning with the supplying of raw material (billets, slugs, blanks), an initial heat treatment/heating, upsetting, pre- and finish forming, trimming, shearing, punching, calibrating, cooling and final heat treatment.
What customers say
"Essentially, we could improve our entire process with regard to process stability, quality, increasing productivity and material savings with the help of simulation. Forming simulation for us stands for advancement, continuous development and cost savings."
Gerald Oppelt, Manager Production Technology, Uponor
Application of the module Hot Forging
The Simufact Forming Hot Forging application module principally serves the simulation of bulk forming operations with starting temperatures above the recrystallization temperature.
Hot die forging, as well as important side processes such as heating and cooling, separation processes and preforming operations (upsetting, bending) are available.
Other typical processes such as (hot) extrusion processes can be modeled with the hot forging module. In combination with the Rolling application module, reducer-rolling and cross wedge-rolling operations can also be simulated. In addition to an early knowledge of the metal flow and integral quantities such as press loads, energy- and work requirements, our customers also have access to our proven and powerful tool Die Load Analysis.
Intuitive templates for all common process types enable realistic virtual testing and optimization under conditions similar to those on the shop floor. The kinematics database includes user-friendly interfaces for commonly available metal forming machines. Once defined, all machine specifications can be saved to the database for later use.
The exclusive dual-solver technology of Simufact Forming (Finite Element and Finite-Volume Solver) gives the user a problem-oriented simulation solution, perfectly tailored to each task. The right selection of the optimal solver technology is supported through appropriate templates.
The level of detail in the simulation model is easily adjustable and ranges from a simple metal flow analysis to the analysis of microstructural evolution with respect to final part properties (Microstructure module); and with the help of the Die Load Analysis, module the study of complex tool systems. The elastic response of the whole machine accounting for stiffness, elasticity, and frame elongations is a standard simulation feature.
Simulation videos Hot Forging
Multi-directional forging: Temperature development during the multi-directional forging of a brass component. Simulated with Simufact.forming Hot Forging.
Precision forging of a helical gear with cyclic symmetry: Use of cyclic symmetry during the forging simulation of helical gears. Example from our Simufact.forming Demos & Examples
Connecting rod: Temperature development during the forging of a connecting rod. Simulated with the Simufact.forming Hot Forging module
Process chain Manufacturing
Simufact Forming Hot Forging enables both two as well as three-dimensional simulations. Individual manufacturing stages along a process chain can automatically be coupled and ensure high throughput and utilization rates of the software.
Application spectrum for Simufact Forming Hot Forging
For the virtual development and optimization of complete manufacturing processes we recommend a combination with the Rolling, Die Analysis and Heat Treatment modules.
All hot die forging-operations (blocker, finisher)
Shearing operations (Cutting)
Heating and cooling
Upsetting / buster operations
The material data base contains approximately 750 material data sets including relevant ferrous and non-ferrous materials and material families.
All typical hot-forgeable steel materials and alloys
Nickel- and titanium-based super alloys.
Wrought aluminum alloys
Non-ferrous metals such as copper and the related alloy systems such as brass and bronze.
Furthermore, the user can import or define external material data via appropriate standard interfaces such as from JMatPro® (Sentesoft).
Metal forming machines
Predefined machine-templates are available for common and typical hot forging machines:
Furthermore, arbitrary motion sequences for several moving tools can be defined in table form. These can be time-, speed-, and stroke- or force-controlled. Real-time machine data can be imported as well if needed.
For the realistic portrayal of your hot forging processes, Simufact.forming can consider numerous boundary conditions for the specific degree of detail of an investigated manufacturing stage:
Homogenous and inhomogeneous heating conditions including thermal expansion of the workpiece through the simulation of the preheating and cooling phases
Consideration of lubrication conditions and surface quality of forming tools via scalable friction models
Temperature dependency of the most relevant physical boundary conditions for more precise calculations
Consideration of elastic spring back and tilting effects of metal forming machines
Fully coupled simulation with elastic-plastically deformable tools
Reach your optimization targets with Simufact.forming Hot Forging
Correct prediction of force-, work-, and energy demands
Determine the optimal stage sequence for your conditions
Perform automatic sensitivity studies of all process stages
Determine the optimal process window with minimized material input, while ensuring a robust manufacturing process
Identify potential manufacturing errors
Maximize of tool life
Verify specifications which cannot be measured online in the real processes
"With approximately 50-60 new projects a year, we save one to two design and try-out loops per project. Without going into specific numbers, it can be estimated that up to five-digit sums arise for each variant."
Volker Berghold, Head of the design department, Schmiedag
Utilize the functional advantages of Simufact.forming Hot Forging
Fast and accurate simulations through the Dual-Solver-Strategy
Reliable and precise fold detection with the Finite Volume Solver while maintaining high calculation speed
Robust, fast and unique definitions of machine elasticity (such as press stiffness)
Continuous application of elastic-plastic and thermal-mechanical coupling in the material model
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