FORGE. world leading numerical simulation software MATERIAL FORMING SIMULATION

Transcription

1 FORGE world leading numerical simulation software MATERIAL FORMING SIMULATION

2 2 3 FORGE is a world leading numerical simulation software for all bulk metal forming processes. It is used both at design and R&D levels by many forming companies and universities worldwide working in various industrial fields. Automotive Defense Aerospace Steel making Construction/Mining Oil and Gas Medical Energy Reduce design cycle Minimize real scale tryouts Increase yield Extend die life Optimize and consolidate quotations

3 4 5 FORGE is a world leading numerical simulation software for all bulk metal forming processes FORGE is best suited for the simulation of hot, warm and cold forming processes of various materials such as: > Steel > Aluminium > Copper > Brass > Titanium > Nickel based alloys > Noble metals Closed die Open die Rolling Hot forging of a connecting rod Ring rolling of an aerospace engine component When it comes to producing forged components the forming industry faces various challenges. Challenges related to the part: Final shape / dimensions Reducer rolling Underfillings / excess material Cross wedge rolling Ring rolling Flow forming Heat treatment: prediction of metallurgic phases Forging of an aerospace blade Folds / laps Porosities / segregations Microstructure Grain flow Final in-use properties Extrusion Challenges related to dies: Wire drawing Deep drawing Shearing Cross wedge rolling of a connecting rod preform Open die forging of a shaft Die life (cracks, wear ) Challenges related to the equipment: Appropriate equipment selection Press jam Piercing Equipment deflection Flash trimming Heat treatment Thread rolling of a screw Quenching of a shell used in the energy field These challenges often lead to costly shop floor trials. With FORGE real scale tryouts are minimized, productivity is increased

4 6 7 FIRST TIME RIGHT DESIGN OF FORGED COMPONENTS FORGE makes it fast and easy to predict accurately: Final shape and dimensions, underfillings and excess material, folds/laps, porosities, grain flow, microstructure. FORGE is the expert simulation solution at the design stage Analyse, master and optimize forming processes, deliver high quality parts on time, on cost and increase productivity. Grain flow analysis of a one-cylinder crankshaft: close correlation between prediction and real part. Fill-up analysis of a stainless steel gas turbine blade. Underfilled area is shown in red. Reduction of excess material of a commercial vehicle sector shaft: initial shape in red and optimized shape in blue. Grain size prediction of a Ni-based alloy disk. Max ASTM value Min ASTM value Actual forging Simulation result Fold/lap analysis: accurate folds/laps prediction of a mining steel component. Fold/lap area is shown in red inside the frame. For the Hirschvogel Automotive Group not only technical but also economic advantages result from the application of the FORGE software. Lately, these have been approved via monetarily assessable as well as non-monetarily assessable criteria. Furthermore the good relationship between Hirschvogel Automotive Group and Transvalor S.A. - which has evolved over more than 10 years of collaboration - is remarkable. Jochen Heizmann, Research & Development, Hirschvogel Umformtechnik GmbH, Denklingen, Germany Porosity evolution in the core of an ingot. Porosities evolution are tracked from casting process and during the complete forging process.

5 8 9 INCREASE DIE LIFE AND OPTIMIZE EQUIPMENT USE FORGE allows the accurate prediction of stress, wear and temperature in the dies, through both coupled or uncoupled analysis applicable over the complete process simulation. FORGE also offers advanced features to optimize and select the appropriate equipment on the shop floor thanks to accurate prediction of forging load and equipment deflection. 6-cylinder crankshaft forging load graph (mechanical press). Uncoupled die stress analysis allowing accurate stress prediction. High stresses are shown in red. Hot forged steel yoke Hirschvogel Umformtechnik GmbH Die crack FORGE offers the most unique advantages for equipment dimensioning and die life extension Actual die Simulation result Thermo-mechanical analysis fully coupled between the dies and the part offering the highest accurate results. Von Mises stress distribution is represented here. Compressive force (MN) max. compressive force - measurement (MN) max. compressive force - simulation (MN) Blow No. Closed correlation between FORGE compressive force prediction and experiment. Buderus Edelstahl GmbH

6 CUTTING EDGE TECHNICAL FEATURES Powerful Unique backward & forward surface tracking features Easy to setup tracking features of points or surfaces: Defect area can be localized in the final geometry, Flash or final shape s position in the initial geometry can be determined. Fully embedded features in the FORGE software Heat treatment capability for the simulation of heating, soaking and quenching. Prediction of phases, hardness, residual stresses and part distortion during quenching. Induction heating feature for the simulation of initial billet heating and heat treatment. Simulation of carburization. The central looseness area of a crankshaft is localized in red. It is set in the initial billet and tracked during the entire forging sequence until the final shape. Prediction of residual stresses after quenching in a crankshaft. Coil Reverse tracking of flash (in blue) up to the initial billet geometry in a saddle (automotive component). Part Prediction of temperature by induction heating in the initial billet of an energy component. Access to the prediction of material flow and geometry of the final shape, distribution of many fields during the complete process: In the workpiece: contact distance to the dies, temperature, displacements, effective strain, strain rate, stresses, damage, folds, microstructure, hardness, metallurgic phases, and many additional user fields. In the dies: temperature, stresses, wear, resulting force and many others.

7 Pioneer and market leader in automatic optimization FORGE includes an automatic optimization feature based on the MAES algorithm (Meta-model Assisted Evolution Strategy). It can be coupled with some CAD packages. In this example, thanks to FORGE optimization feature linked with a CAD system, the initial billet weight has been reduced by 10% per part. Extensive Databases Press and equipment kinematics available and filtered to comply with product and process selection: Hydraulic press, hammer, counter blow hammer, knuckle joint press, mechanical press, multi-speed hydraulic press, screw press, link drive press, orbital forging press, incremental forging press, rotary swaging, forging machine, rolling mills including ring rolling. Automatic parameters setting in the CAD system. Flash pattern before (in red) and after optimization (in blue). AUTOMATIC OPTIMIZATION Numerical facts Fast, accurate and efficient 2D and 3D Finite Element simulation software based on the use of 4-node triangles and 5-node tetrahedra, best suited elements for complex shapes Implicit solver for accurate stress prediction and volume conservation Fully parallel up to 64 computer cores: solving, automatic remeshing and mapping are done in parallel on each core Updated Lagrangian approach and Arbitrary Langrangian Eulerian for well suited processes Bi-mesh technique allowing CPU time reduction for localized deformation processes Automatic adaptative time step User variables and subroutines can be defined and visualized in the graphical post processing interface Automatic optimization feature based on the MAES algorithm (Meta-model Assisted Evolution Strategy) and coupling of optimizer with CAD packages. The analysis carried out with FORGE to model the evolution of defects in Aeroengine disk forging would not have yielded results this close to experimental values on many other metal forming software products. FORGE has a unique multi body approach to modeling such complicated phenomena which enhances the simulation capabilities of processes. Rajiv Shivpuri, Manufacturing Research Group Ohio State University, Columbus OH USA Extensive material database for forming and heat treatment processes Over 1000 materials are available in our database. Integration of your own material dataset is possible in tabulated format. Feature to import from Sente Software JMatPro. Wide range of friction laws. Non-uniform friction coefficient and HTC for the same die.

8 CUTTING EDGE TECHNICAL FEATURES Fast Market leader in parallel computation and numerical techniques to reduce computation time Pioneer in parallel computation FORGE offers the highest scalability allowing more accurate results within very short computation times. AREVA Creusot Forge Computation time X1.2 FASTER X2 FASTER X3 FASTER FORGE runs on various Windows and Linux platforms, from standard workstations to multi-core High Performance Computing clusters. X2 FASTER X3.7 FASTER 4 cores 6 cores 12 cores 24 cores FORGE embeds a new bi-mesh technique for CPU demanding processes with localized deformation such as becking, cogging and incremental forging. Computation time versus number of computer cores for the complete forging sequence (5 stages) of a steering sector shaft. Parallel computation efficiency is 80 % on this simulation. This method allows significant CPU time reduction while retaining similar result quality.

9 CUTTING EDGE TECHNICAL FEATURES Flexible & Easy to Use Geometry import Interface with most available CADs through neutral formats such as STEP, STL, UNV, Nastran/Patran, Parasolid. Result export interface in DXF (for 2D simulations) and STL, UNV and Ansys file formats (for 3D simulations). Batch processing and simulation chaining for increased productivity. Automatic simulation report including setup data summary, selected results and computation details. Unmatched Flexibility FORGE solver FORGE provides the highest flexibility with unlimited access to the Graphical User Interface for 64-bit pre and post processing. License fees are related to the number of computer cores regardless of the number of users. Extra flexibility benefits are: Job scheduling 2D and 3D automatic transitions between stages Dynamic token allocation across multiple and remote sites (Floating License) > User #5 > User #1 Solver support for up to 64 cores in parallel (one simulation can be executed on 64 cores concurrently) Token borrowing > User #2 > User #3 > User #4

10 Customer services Regular new releases and Service Packs when required. Customer support through NetViewer. Customer on-site training on request. Frequent customer visits. User meetings are held wordwide on an annual basis. All processes and all features mentioned in this brochure are available in the FORGE software with no additional cost

11 TRANSVALOR S.A. Parc de Haute Technologie 694, avenue du Dr. Maurice Donat Mougins Cedex - France Phone: +33 (0) Fax: +33 (0) marketing@transvalor.com FORGE world leading numerical simulation software TRANSVALOR has been certified ISO 9001: 2008 by the Bureau Veritas Quality International (BVQI) for the development, industrialisation and licensing of computed-aided engineering software and related services. This certification shows the will of TRANSVALOR to progress and to answer better its customers expectations. FORGE is a trade mark of TRANSVALOR S.A. - non-contractual Document - Design Emmanuel Briot - PrintCentre