Top key features of the previous Simufact Forming versions

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.

Simufact Forming 15 New Features

Button SF V 15

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 15 Release Updates
  • Design and optimize inductive heating processes
  • Simulate case hardening in Simufact Forming 15
  • Improved positioning capabilities by redesigned positioner
  • ...

Design and optimize inductive heating processes

App. Design and optimize inductive heating processes
Design and optimize inductive heating processes

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.

Simulate case hardening in Simufact Forming 15

App. Simulate case hardening in Simufact Forming 15
Simulate case hardening in Simufact Forming 15

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.

Improved positioning capabilities by redesigned positioner

App. Improved positioning capabilities by redesigned positioner

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.

Make simulation evaluation more intuitive and efficiently by query results functionality

App. Make simulation evaluation more intuitive and efficiently by Query results functionality
Make simulation evaluation more intuitive and efficiently by Query results functionality

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.

Compare simulation and reference model

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.

App. Compare simulation and reference model
Compare simulation and reference model

Automatic fold detection feature

App. Automatic fold detection feature
Automatic fold detection feature

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.

Automatic measurement of spot welds

App. Automatic measurement of spot welds
Automatic measurement of spot welds

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.

Process chain: Interface between casting and forming simulation software

App. Process chain: Interface between casting and forming simulation software
Process chain: Interface between casting and forming simulation software

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.

Simufact Forming 14 Novelties

Button SF V 14

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 14 Release Updates
  • GUI View – Improved operational concept
  • New module Pressure Welding
  • Rolling operations now included in the Forming Hub
  • ...

GUI View – Improved operational concept

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.

GUI View – Improved operational concept
GUI View – Improved operational concept

New module Pressure Welding

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.

New module Pressure Welding
New module Pressure Welding

Rolling operations now included in the Forming Hub

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.

Forming HUB includes Rolling module
Forming HUB includes Rolling module

New Process types in Mechanical Joining

New Process types in Mechanical Joining
New Process types in Mechanical Joining

The Mechanical Joining application module in Simufact Forming 14 offers new process types:

  • Self-Pierce-Riveting
  • Punch Riveting
  • Blind Riveting
  • Tensile Test

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.

Joining Optimizer - automatic validation of self-piercing-riveting and clinching processes

Joining Optimizer GUI
Joining Optimizer GUI

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

Automated serial evaluations

Automated serial evaluations
Automated serial evaluations

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.

Process chain simulation: Interface to casting simulations

Process chain simulation: Interface to casting simulations and representation of the density in the workpiece
Process chain simulation: Interface to casting simulations and representation of the density in the workpiece

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.

Industry 4.0: Coupling process simulation and process monitoring

Industry 4.0: Coupling process simulation and process monitoring. Source right: Brankamp GmbH Process Monitoring System PROKOS X7
Industry 4.0: Coupling process simulation and process monitoring. Source right: Brankamp GmbH Process Monitoring System PROKOS X7

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.

Enhanced material database

Enhanced Simufact Materials database provides electromagnetic properties
Enhanced Simufact Materials database provides electromagnetic properties

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.

Simufact.forming 13 Release Updates

Button SF V 14

This version not only offers a range of functional enhancements, but also improvements in post processing, result accuracy, software stability, and speed.

Simufact Forming 13 Release Updates
  • User-defined Parameters
  • Tracking of Post Particles
  • Mechanical Joining improvements
  • ...
Simufact.forming 13 product box

Simufact.forming 13 is available.

The cover of the new Simufact.forming 13 software box illustrates the simulation of a forged conrod and a mechanical joining process chain.

  • User-defined Parameters: With user-friendly mathematical formulas, users can now generate their own parameters based on those of the simulation. This function simplifies the post processing needed when examining the variables in the design process. Routine designs can be automatically evaluated, which substantially cuts down the time taken to find the best design for the manufacturing process.
  • Tracking of Post Particles: Post particle tracking helps users finding the causes of typical mistakes in a massive forming process. Post particles are user-defined measuring points for the parameters. The user can define them after the actual simulation, during post processing, and during all process steps whilst running the simulation both forward and backward.
  • Mechanical Joining improvements: Users applying Simufact.forming for the simulation of mechanical joining, profit from several new developments. The special parameters used in hollow self-pierce riveting processes are automatically determined and shown. Users can quickly evaluate the highly realistic results of the simulation with just the push of a button. Furthermore, predefined templates now support the design of self-pierce riveting processes
  • Shared-Memory Parallelization: The more powerful shared-memory parallelization (SMP) replaces multiple-threading parallelization. SMP reduces computation times by up to 50 percent when calculating with an FE solver by implementing an additional parallelization to the assembly of the stiffness matrix. Computation times with the FV solver are shortened by 10 to 25 percent.
  • Status display for remote synchronizing: An addition to the progress of the simulation is the expanded status bar that now displays the state of remote synchronizing - and the transfer of the simulation results to the local client. This function is useful for client-server installations where calculations are done on network resources rather than on the client.
  • Automatic definition of symmetry levels: The automatic definition of symmetry levels saves the user the time and effort it would take to manually define the levels and the time and effort needed to adjust the press force and maximum force.
  • Export results using the I-DEAS Universal format: Simulation results can now be exported for further use in the I-DEAS Universal format, e.g. for a subsequent structure simulation.

 

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