FORGE world leading numerical simulation software
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
FORGE
world leading
numerical simulation
software
M AT ER I AL F O RMIN G SIMUL AT IO N
2 www.transvalor.com 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 Reduce design cycle
Minimize real scale tryouts
Aerospace Energy
Steel making Increase yield
Construction/Mining Extend die life
Oil and Gas
Medical Optimize and consolidate quotations
4 www.transvalor.com 5
FORGE is a world leading FORGE is best suited for the simulation of hot, warm and cold forming
processes of various materials such as:
numerical simulation software
> Steel > Aluminium > Copper > Brass
for all bulk metal > Titanium > Nickel based alloys > Noble metals
forming processes
When it comes to producing forged
Closed die
components the forming industry
Open die faces various challenges.
Hot forging Ring rolling of an
of a connecting rod aerospace engine Challenges related to the part:
Rolling component Final shape / dimensions
Reducer rolling Underfillings / excess material
Folds / laps
Cross wedge rolling
Porosities / segregations
Heat treatment: prediction
Ring rolling of metallurgic phases Microstructure
Forging of an
aerospace blade Grain flow
Flow forming
Final in-use properties
Extrusion
Challenges related to dies:
Wire drawing Cross wedge rolling Die life (cracks, wear…)
of a connecting
Deep drawing rod preform
Open die forging
Challenges related to the equipment:
of a shaft Appropriate equipment selection
Shearing
Press jam
Piercing Equipment deflection
Flash trimming Thread rolling
Quenching of a shell
These challenges often lead to costly
of a screw
used in the shop floor trials.
Heat treatment energy field
With FORGE real scale tryouts are
minimized, productivity is increased
6 www.transvalor.com 7
FIRST TIME RIGHT DESIGN FORGE is the expert
simulation solution
OF FORGED COMPONENTS at the design stage
FORGE makes it fast and easy to predict accurately:
Analyse, master and optimize forming
Final shape and dimensions, underfillings and excess material, processes, deliver high quality parts on
folds/laps, porosities, grain flow, microstructure. 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 Reduction of excess material of a
stainless steel gas turbine commercial vehicle sector shaft:
blade. Underfilled area is initial shape in red and Grain size prediction Max ASTM value
shown in red. optimized shape in blue. of a Ni-based alloy disk.
Min ASTM value
Actual Simulation
forging 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 Porosity evolution in the core of an ingot.
application of the FORGE software. Lately, these have been approved via monetarily assessable as well as Porosities evolution are tracked from casting
non-monetarily assessable criteria. Furthermore the good relationship between Hirschvogel Automotive Group process and during the complete forging process.
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
8 www.transvalor.com 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
FORGE offers the most unique
shown in red. Die crack advantages for equipment
Hot forged steel yoke
Hirschvogel Umformtechnik GmbH
dimensioning and die life extension
Actual Simulation
die result 120
110
100
90
Compressive force (MN)
80
Thermo-mechanical analysis fully coupled 70
between the dies and the part offering the 60
highest accurate results. Von Mises stress
distribution is represented here. 50
40
30
Closed correlation between
20
FORGE compressive
10 max. compressive force - measurement (MN)
max. compressive force - simulation (MN)
force prediction and
0 experiment.
0 5 10 15 20 25 30 Buderus Edelstahl GmbH
Blow No.
10 www.transvalor.com 11
CUTTING EDGE TECHNICAL FEATURES Fully embedded features
in the FORGE software
Powerful Heat treatment capability for the simulation
of heating, soaking and quenching. Prediction
of phases, hardness, residual stresses and part
distortion during quenching.
Unique backward & forward surface tracking features
Induction heating feature for the simulation of
Easy to setup tracking features of points or surfaces: initial billet heating and heat treatment.
Defect area can be localized in the final geometry,
Simulation of carburization.
Flash or final shape’s position in the initial geometry can be determined.
Prediction of residual stresses after
quenching in a crankshaft.
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.
Coil
Part
Reverse tracking of flash (in blue) up to the initial billet
geometry in a saddle (automotive component). 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.
12 www.transvalor.com 13
Pioneer and market leader Extensive
in automatic optimization Databases
FORGE includes an automatic optimization feature based on the MAES algorithm Press and equipment kinematics available and filtered to comply
(Meta-model Assisted Evolution Strategy). It can be coupled with some CAD packages. with product and process selection:
In this example, thanks to FORGE optimization feature linked with a CAD system, the initial
billet weight has been reduced by 10% per part. 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
Extensive material database
Numerical facts for forming and heat treatment
processes
Fast, accurate and efficient 2D and 3D Finite Element simulation Over 1000 materials are available in our
software based on the use of 4-node triangles and 5-node tetrahedra, database. Integration of your own material
best suited elements for complex shapes “The analysis carried out with
FORGE to model the evolution of dataset is possible in tabulated format.
Implicit solver for accurate stress prediction and volume conservation defects in Aeroengine disk forging
Fully parallel up to 64 computer cores: solving, automatic remeshing would not have yielded results this Feature to import from Sente Software JMatPro.
and mapping are done in parallel on each core close to experimental values on
many other metal forming software Wide range of friction laws.
Updated Lagrangian approach and Arbitrary Langrangian Eulerian for
products. FORGE has a unique
well suited processes Non-uniform friction coefficient and HTC
multi body approach to modeling
Bi-mesh technique allowing CPU time reduction for localized such complicated phenomena for the same die.
deformation processes which enhances the simulation
Automatic adaptative time step capabilities of processes.”
User variables and subroutines can be defined and visualized in the
Rajiv Shivpuri, Manufacturing
graphical post processing interface
Research Group
Automatic optimization feature based on the MAES algorithm Ohio State University, Columbus
(Meta-model Assisted Evolution Strategy) and coupling of optimizer OH USA
with CAD packages.
14 www.transvalor.com 15
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
X2
FASTER
X3
Computation time
FASTER
X1.2
FASTER
FORGE embeds a new bi-mesh
X2 technique for CPU demanding
FASTER
processes with localized
X3.7
FORGE runs on various Windows and Linux platforms, FASTER deformation such as becking,
from standard workstations to multi-core High cogging and incremental
Performance Computing clusters. 4 cores 6 cores 12 cores 24 cores forging.
Computation time versus number of computer cores This method allows significant
for the complete forging sequence (5 stages) of a CPU time reduction while
steering sector shaft. Parallel computation efficiency retaining similar result quality.
is 80 % on this simulation.
16 www.transvalor.com 17
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 > User #1 > User #5
Dynamic token allocation across multiple and remote sites (Floating License)
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
18 www.transvalor.com 19
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
www.transvalor.comFORGE is a trade mark of TRANSVALOR S.A. - non-contractual Document - Design Emmanuel Briot - PrintCentre
TRANSVALOR S.A.
Parc de Haute Technologie TRANSVALOR has been certified ISO 9001:
2008 by the Bureau Veritas Quality
694, avenue du Dr. Maurice Donat International (BVQI) for the develop-
06255 Mougins Cedex - France ment, industrialisation and licensing of
computed-aided engineering software
Phone: +33 (0)4 92 92 42 00 and related services.
This certification shows the will of
Fax: +33 (0)4 92 92 42 01 TRANSVALOR to progress and to answer
Email: marketing@transvalor.com better its customers’ expectations.
FORGE world leading
numerical simulation
softwareYou can also read
