This film shows the possibilities to simulate different forging applications with FORGE® simulation software.
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00:02 - 00:14 FORGE® models the real process including hot or cold billet shearing to evaluate the profile of the sheared area, local plastic strain, residual stresses and press load.
►Reducer Rolling + Forging:
00:18 - 00:27 Reducer rolling is a typical operation to get a well-balanced preform prior to forging.
►Crankshaft - Forging:
00:49 - 01:16 Closed-die forging simulation is used for multiple purposes: to FORGE® validates the forging sequence for quotation purposes, to solves shop-floor issues and to optimizes the forging yield of existing components.
►Central looseness tracking:
01:16 - 01:19 Easy following of segregations at the center of the billet
►Flash reverse tracking:
01:20 – 01:26 Backward flash tracking to locate areas with excess of material and consequently to optimize billet preform.
►Connecting Rod - Cross Rolled Preform
01:31 – 01:56 FORGE® simulates the metal flow occurring during CWR. It detects potential defects due to the Mannesman effect and considers the real kinematic applied on the rolls.
02:02 – 02:14 FORGE® perfectly handles tooling analysis with multiple deformable bodies.
02:15 – 02:24 Unrivaled remeshing capabilities and solver robustness to simulate trimming or piercing operations.
02:25 – 02:48 Ring rolling process is used to produce seamless rings starting from a donut-shaped preform. Parts are typically made of stainless steels, nickel or titanium alloys.
02:49 – 03:04 For aerospace applications, FORGE® can simulate a large variety of parts (engine disk, fan or turbine blade, landing gear, …) made of nickel-based superalloys, titanium or aluminium grades.
►Reverse Point Tracking
03:05 – 03:13 FORGE® embeds unique tracking features predict surface folds/laps, fibering, grain flow, underskin defects and much more.
►Cogging - Ingot solidification
03:14 – 03:41 TRANSVALOR is the unique software editor in the field of forming process simulation to ensure the complete workflow from casting to forging. Porosity: closing prediction during forging is done from distribution at the end of solidification. Areas with enriched carbon concentration/depletion can be tracked up to the end of forging.
03:43 – 03:52 Simulate continuous rolling to anticipate product imperfections (hot tearing, twisting, ripple effect).
03:53 – 04:07 Incremental forming process is a standard process which allows significant reduction of the press load.
04:08 – 04:33 FORGE® addresses major open-die forging processes: cogging, becking, mandrel drawing, blooming. The bi-mesh method grants important CPU time reduction.
04:34 – 04:53 Based on TTT/CCT diagrams, FORGE® simulates quenching of forgings dropped into a water pool. Output results are: temperature, phase transformation, residual stresses and part distortion.
04:55 – 05:26 Flow forming or metal spinning processes make it possible to obtain cylindrical parts with complex shapes by reducing thicknesses.
05:27 – 05.35 Control thickness and eccentricity variations during rolling of long products.
05:38 – 05:48 Simulation of non-ferrous metals and alloys with excellent resistance to corrosion and very good electrical conductivity is possible with FORGE®: Bronze, Brass, Copper, Aluminum.
05:49 – 06:00 FORGE® addresses various fastening techniques: clinching, riveting, crimping with multiple materials.
06:01 – 06:09 …For fastening/tightening simulations, FORGE® genuine elasto-plastic behavior allows the accurate calculation of residual stresses as well as potential damage of the components.
06:10 – 06:20 Simulation of high-quality fasteners: from forging up to final thread rolling stage. Real kinematics applied on the chaser dies, smart rotational update scheme that ensure fastener volume conservation during the simulation.