M A T E R I A L F O R M I N G S I M U L A T I O N
FORGE
world leading
numerical simulation
software
Automotive
Construction/Mining
Aerospace
Defense
Oil and Gas
Energy
Steel making
Medical
Increase yield
Minimize real scale tryouts
Extend die life
Optimize and consolidate quotations
Reduce design cycle
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.Closed die Open die Rolling
Reducer rolling Cross wedge rolling Ring rolling Flow forming Extrusion Wire drawing Deep drawing Shearing Piercing Flash trimming Heat treatment
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
FORGE
is a world leading
numerical simulation software
for all bulk metal
forming processes
With
FORGE
real scale tryouts are
minimized, productivity is increased
When it comes to producing forged
components the forming industry
faces various challenges.
Challenges related to the part:
Final shape / dimensions Underfillings / excess material Folds / laps
Porosities / segregations Microstructure
Grain flow
Final in-use properties
Challenges related to dies:
Die life (cracks, wear…)
Challenges related to the equipment:
Appropriate equipment selection Press jam
Equipment deflection
These challenges often lead to costly
shop floor trials.
Hot forging
of a connecting rod Ring rolling of an aerospace engine component
Forging of an aerospace blade
Open die forging of a shaft
Quenching of a shell used in the
energy field Heat treatment: prediction
of metallurgic phases
Cross wedge rolling of a connecting rod preform
Thread rolling of a screw
FIRST TIME RIGHT DESIGN
OF FORGED COMPONENTS
FORGE makes it fast and easy to predict accurately:
Actual
forging
Simulation
result
Final shape and dimensions, underfillings and excess material, folds/laps, porosities, grain flow, microstructure.
FORGE
is the expert
simulation solution
at the design stage
“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
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.
Grain flow analysis of a one-cylinder crankshaft: close correlation between prediction and real part.
Porosity evolution in the core of an ingot. Porosities evolution are tracked from casting process and during the complete forging process.
Analyse, master and optimize forming processes, deliver high quality parts on time, on cost and increase productivity.
Max ASTM value Min ASTM value
Fold/lap analysis: accurate folds/laps prediction of a mining steel component. Fold/lap area is shown in red inside the frame.
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.
Uncoupled die stress analysis allowing accurate stress prediction. High stresses are shown in red. Hot forged steel yoke Hirschvogel Umformtechnik GmbH
6-cylinder crankshaft forging load graph (mechanical press).
INCREASE DIE LIFE AND OPTIMIZE
EQUIPMENT USE
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.
120 110 100 90 80 70 60 50 40 30 20 10 0 Compressiv e forc e (MN) Blow No.
max. compressive force - measurement (MN) max. compressive force - simulation (MN)
0 5 10 15 20 25 30
Closed correlation between FORGE compressive force prediction and experiment.
Buderus Edelstahl GmbH
8 www.transvalor.com 9
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.
CUTTING EDGE TECHNICAL FEATURES
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.
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.
Prediction of temperature by induction heating in the initial billet of an energy component.
Coil
Part Reverse tracking of flash (in blue) up to the initial billet
geometry in a saddle (automotive component).
Powerful
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.
Fully embedded features
in the FORGE software
www.transvalor.com
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.
Automatic parameters setting in the CAD system.
AUTOMATIC
OPTIMIZATION
Flash pattern before (in red) and after optimization (in blue).
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.
Extensive
Databases
Press and equipment kinematics available and filtered to comply
with product and process selection:
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.
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.
Numerical facts
“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
FORGE embeds a new bi-mesh technique for CPU demanding processes with localized deformation such as becking, cogging and incremental forging.
This method allows significant CPU time reduction while retaining similar result quality.
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.
© AREVA Creusot Forge
FORGE runs on various Windows and Linux platforms, from standard workstations to multi-core High Performance Computing clusters.
Pioneer in parallel computation FORGE offers the highest scalability allowing more accurate results within very short computation times.
4 cores 6 cores 12 cores 24 cores
C
omputa
tion time
CUTTING EDGE TECHNICAL FEATURES
Fast
Market leader in parallel computation and
numerical techniques to reduce computation time
X3 FASTER X2 FASTER X1.2 FASTER X2 FASTER X3.7 FASTER
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.
CUTTING EDGE TECHNICAL FEATURES
Flexible & Easy to Use
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)
Solver support for up to 64 cores in parallel (one simulation can be executed on 64 cores concurrently)
Token borrowing
Unmatched Flexibility
> User #1
> User #2
> User #3
> User #4
> User #5
FORGE
solver
www.transvalor.com
All processes and all features mentioned in this brochure are available
in the FORGE software with no additional cost
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.
FORGE
world leading
numerical simulation
software
Parc de Haute Technologie
694, avenue du Dr. Maurice Donat 06255 Mougins Cedex - France Phone: +33 (0)4 92 92 42 00 Fax: +33 (0)4 92 92 42 01
Email: [email protected]
TRANSVALOR S.A.
TRANSVALOR hAS beeN ceRTified iSO 9001: 2008 by The buReAu VeRiTAS QuALiTy iNTeRNATiONAL (bVQi) fOR The deVeLOp-meNT, 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.
FOR GE is a trade mark o f TR ANSV AL OR S.A . - non-c ontractual Document
- Design Emmanuel Briot
- P
rintC
