On this site we have summarized the top key features of the recent releases on Simufact Forming. Please read and watch the videos to get an overview on the top highlights of each respective version.
Do you want to know which key features we have implemented in the previous versions? Familiarize yourself with the top new key features of each respective versions. Please note that we only provide the key features for the last three versions.
With Simufact Forming 2021, the user benefits from new integrated tetrahedral elements for meshing. They provide him a much faster calculation and ensure highest accuracy at the same time, compared to existing tetrahedral elements in Simufact Forming 16.
The user only needs to change the element type to the new integrated tetrahedral elements and speeds up his process simulation up to 2.8x faster as in the previous version.
For the first time, Simufact introduces an assistant for damage modelling in Simufact Forming 2021. It convinces by its ease of use and the user benefits from increasing accuracy.
The damage model for itself has an enormous impact on the accuracy predicting the damage occurrence as well as the force progression. The creation and consideration of a damage model in the simulation has been very difficult to impossible until now.
In Simufact Forming 2021, the user enters the damage characteristics, such as equivalent strain and the averaged Lode angle at failure. The new damage modelling assistant automatically calculates, generates and calibrates the damage model. Finally, the user benefits from the newly generated damage model, which enables accurate calculations in the future.
A new Finite-Volume-Method (FVM) solver has been implemented in Simufact Forming 2021, called ‘Accelerated FVM solver’. It impresses with up to 1.5x times faster calculations compared to the existing FVM solver.
For the user of Simufact Forming 2021, it is now easier than ever to increase his calculation speed at the same accuracy for bulk metal forming simulation. He simply changes the solver type in the process definition and enjoys the speed-up in Simufact Forming 2021.
With Simufact Forming 2021, after process simulation, the user looks forward to structure simulation with basic functionalities. The structural simulation helps him, among other things, to determine the maximum load before the component fails and the force progression of a dynamic load.
In addition, with this new feature, the user has the possibility to simulate new process types, such as hydroforming.
Thanks to this new feature, the user can transfer his process simulation results from the software into any format by the help of the MpCCI Mapper interface. It provides advanced and robust methods to map, compare and transfer simulation results and experimental data in integrated simulation workflows. Thus, the user benefits from the capability to transfer his results from 3rd party products prior to Simufact Forming and afterwards.
Our user enjoys a great number of modernizations in Simufact Forming 2021: The GUI of Simufact Forming 2021, the icons, the product window, the splash screen as well as the installation wizard.
In addition, our version numbers of any new software release have changed starting with Simufact Forming 2021. In the future, further feature packs will be referred to as 2021.1 and service packs as 2021.0.1.
Overall, 1515 improvements (new features, bug fixes, documentation and other improvements) have been incorporated in Simufact Forming 2021 – and make them the fastest and most stable version ever!
Highlights in version 16, amongst others: the fast and efficient modelling capability for complex manufacturing processes and new functionality that helps build robust simulation models.
With just a few clicks of the mouse, users can work at speed and model complex manufacturing processes more efficiently.
With the improved memory handling, the improved Graphical User Interface (GUI) and the intelligent context menus and integrated dialogue, it is incredibly easy to use.
In addition to the model set up, model evaluation using post particles (virtual sensors) it is distinctly faster than the previous version.
Defective tool geometries can lead to simulation crashes or have a negative effect on the quality of the meshing. With the newly implemented functionality for the geometry data check, the user can set up robust simulation models. Just one click is needed to identify geometry defects as well as their positions within the component. The generated knowledge helps the user to repair the errors within the CAD system.
As a result, the user can retrace all corrections that have been made.
The user imports the optimized tool geometries into Simufact Forming 16 and continues setting up the model.
Version 16 offers the expansion of 3D features which enables the user to utilise the symmetry properties to extend the visualization up to 360 degrees using mirror and axial symmetry features regardless of their position in the
space. The full 3D visualization provides a comprehensive understanding of the results, which enables a deeper understanding of the process.
Another feature is the extended scope of post particles (virtual sensors), which delivers measurements of deformable dies and 2D simulations. The user can use these at any position for the evaluation.
In Simufact Forming, compared to 3D full models, the user saves considerable computing time while retaining practice-oriented full 3D visualisation. This feature has an extended application scope which provides a particularly effective method and reduces calculation time.
This method is based on the calculation of selected workpiece segments and leveraging their symmetry properties. The user has the possibility to adjust the workpiece segments at every single forming stage if needed.
With Simufact Forming 16, users can easily compare the simulated model with a reference model (e.g. a CAD model or measured surfaces) using the “best-fit method” to evaluate if tolerances will be met. Here the software automatically determines the position with the highest deviation and highlights it in the result view. For this function, Simufact has integrated Hexagon’s 3DReshaper technology.
Furthermore, Simufact Forming 16 offers the cut outline functionality to directly compare the simulated geometry with the target- geometry. For further evaluation the user can export the results into CAD-systems.
It takes only one click to import model data and results from Simufact Welding or Simufact Additive in the latest version of Simufact Forming. Users can, for example, import two previously welded components from Simufact Welding into Simufact Forming and continue by modelling a forming process. Thus, minimal effort is needed to achieve a consistent process chain simulation.
Moreover, the user is able to exchange or transfer data between different Simufact Forming projects. Thus, the user can import selected processes with all process properties and use them for subsequent calculations.
Beyond the scope of the Simufact product family, Version 16 also provides users with enhanced flexibility in terms of sharing results with any CAE product. The user can use the exported simulation results in any other products, for example for fatigue simulation. While importing, Simufact Forming 16 interprets the different variants of the UNV files, unless they conform to the UNV standard definition or contain custom result types. Likewise, the user can export his results adapted to the target software.
Simufact Forming 16 enhances its performance in data management by implementing the archiving manager so users can reduce the data from large projects automatically which in turn reduces archiving costs. While doing so, the result steps used in forming stage transitions can be retained and archived.
Two highlights in Simufact Forming 15 let beat the hearts of forming users faster: inductive heating and case hardening. In addition, further technical improvements such as the re-designed positioner and query results ensure an even more intuitive and efficient evaluation of the simulation results. Familiarize yourself with the top new features of Simufact Forming 15.
Simufact Forming helps design engineers gain a detailed insight into an inductive heating process. Users can identify errors, remove unwanted effects, and make optimizations. For example, designing the coil, which is the core challenge of inductive heating. Simufact Forming 15 presents users with the complexity of physical context.
The required electromagnetic material properties needed for these types of workflow can be imported by the extended JMatPro interface.
Simufact Forming Version 15 extends the functions of simulating heat treatment processes in order to make practical use of the diffusion effects in case hardening.
With the new version, it is now possible to calculate the adjusting carbon distribution that results during the carburizing below the surface of the component, and allows for the influence of this carbon profile on the transformation behavior during quenching. With this function, the user can make statements about expected case hardening depths, distortions, and residual stresses without the physical testing.
The newly implemented contact positioner and the significantly improved positioning options simplify the positioning of the workpiece and the tools in the software solution. Individually users can position the respective components in the software and thus save time during model building.
With the query results function (querying values), engineers can selectively record and determine result quantities. Simply clicking on a point in the workpiece or in the tool, and the simulation software automatically opens a dialog with results in a clear and accurate table. The CSV file exports via the Excel connection, so users can then proceed with next steps such as the graphic preparation and evaluation of the results.
With the newly implemented user coordinate system, users can compare their simulated component with the target design or with 3D measurement data as a reference model. For this, they import their measurement data from the measurement software of the CAD system into the user interface of Simufact Forming 15 and compare the simulated workpiece with the target design.
With the current version, Simufact introduces a re-implemented fast and automated fold detection feature that greatly simplifies the detection of folds, which is specifically useful for hot forging. During the simulation process, the software places markers on areas with possible folds. Users will be able to detect the possible folds during the analysis without increasing the simulation time.
The automatic measurement of the weld nugget facilitates the evaluation of resistance spot welds of relevant joint parameters, such as measuring the welding nugget geometry. This function allows the engineer to check quickly and easily the quality criteria of this joint.
A further new feature is the interface to the casting software Magmasoft 5.4 which, in addition to the already existing ProCAST interface, pushes forward the idea of process chain simulation. Results imported from the casting simulation via the Magma interface can be used in Simufact Forming 15 for subsequent forming processes.
The new version of Simufact Forming 14 convinces by improvements in the model set up as well as in the evaluation of results. In addition, the new application module Pressure Welding enables the simulation of mechanical-thermal processes.
Simufact Forming comes with a newly developed GUI operation concept: Highly interactive context-related user dialogs allow for a direct access to all relevant settings, which provides a completely new handling experience. Users benefit from an ease-of-use modelling procedure via mouse or touchpad, and finally a higher productivity in results evaluation.
The new application module Pressure Welding allows for simulating Resistance Welding processes, which includes Friction Welding, Friction Spot Welding, and Resistance Spot Welding. Generally spoken, pressure welding stands for a group of processes which join components by heating by friction or electrical current in combination with compression. The module´s functionality puts its focus on the process simulation and helps examine the single welding spot – combining forming and thermal joining aspects. Pressure welding processes are often employed in Hot Forging for Electrical Upsetting. Cold forming companies benefit from pressure welding since this module allows for prolonging their process chain for subsequent projection welding processes.
With Simufact Forming 14, all users obtain full access to the rolling module since it is included in the Forming Hub now. Customers employed with Hot Forging, Cold Forming and other processes requested a general availability of rolling simulation functionality since rolling is a typical pre-forming process.
The Mechanical Joining application module in Simufact Forming 14 offers new process types:
When choosing a dedicated process type the software provides application-specific pre-settings, which reduces efforts for the model design and shortens pre-processing time.
In addition, the Mechanical Joining module comes with new automation capabilities for model design (pre-processing), and evaluation of the most relevant geometrical parameters (post-processing). The positioning and simulation of adhesives has been further improved.
The Joining Optimizer is a new add-on tool available for Simufact Forming – serving as an efficient solution in car body manufacturing. It shortens development times by automatic validation of self-piercing riveting and clinching processes. Simufact has developed the Joining Optimizer in cooperation with Audi, which is employing this solution in their productive environment
Simufact Forming is now supporting automatic serial evaluations of tool geometries and boundary conditions. This functionality can be used for automated try-out of alternative die designs and for process stability examinations.
Simufact Forming now provides an interface for data import from ProCAST (ESI), one of the most widespread casting simulation software applications. The interface allows to smoothly import casting simulation results like porosity and segregations into Simufact Forming for subsequent forming simulation (e.g. in open die forging) – in order to predict the position of segregations in the forged part and the remaining porosity.
Presented at the wire show 2016 by the example with cold forming specialist Moehling – now it´s available in the product: Simufact Forming 14 comes with an interface to Brankamp process monitoring systems. By linking process simulation with process monitoring, Simufact and Brankamp remarkably contribute to the Industry 4.0 idea and open up new beneficial approaches for cold forming companies. Allows the use of a set-point and actual comparison of measured and simulated forces to be set up in the same way as the process was previously simulated or optimized: "Manufactured as simulated". As a result, the tool life can be increased during cold forming.
In cooperation with MatCalc Engineering, Simufact has added an interface for the import of high-quality aluminum material data. This improves Simufact Forming capabilities for simulating aluminum forming processes.
In addition, Simufact has enhanced their JMatPro interface and the Simufact Materials database for electrical material properties.
This version not only offers a range of functional enhancements, but also improvements in post processing, result accuracy, software stability, and speed.
The cover of the new Simufact.forming 13 software box illustrates the simulation of a forged conrod and a mechanical joining process chain.
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