forge - Transvalor

FORGE
world leading
numerical simulation
software
M AT ER I AL   F O RMIN G  SIMUL AT IO N
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www.transvalor.com
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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 Energy
Steel making
Construction/Mining
Oil and Gas
Medical
Reduce design cycle
Minimize real scale tryouts
Extend die life
Increase yield
Optimize and consolidate quotations
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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
When it comes to producing forged
components the forming industry
faces various challenges.
Closed die
Open die
Rolling
Hot forging
of a connecting rod
Ring rolling of an
aerospace engine
component
Folds / laps
Cross wedge rolling
Heat treatment: prediction
of metallurgic phases
Flow forming
Porosities / segregations
Forging of an
aerospace blade
Deep drawing
Cross wedge rolling
of a connecting
rod preform
Die life (cracks, wear…)
Open die forging
of a shaft
Challenges related to the equipment:
Appropriate equipment selection
Press jam
Equipment deflection
Piercing
Heat treatment
Grain flow
Challenges related to dies:
Shearing
Flash trimming
Microstructure
Final in-use properties
Extrusion
Wire drawing
Final shape / dimensions
Underfillings / excess material
Reducer rolling
Ring rolling
Challenges related to the part:
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
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FORGE is the expert
simulation solution
at the design stage
FIRST TIME RIGHT DESIGN
OF FORGED COMPONENTS
FORGE makes it fast and easy to predict accurately:
Analyse, master and optimize forming
processes, deliver high quality parts on
time, on cost and increase productivity.
Final shape and dimensions, underfillings and excess material,
folds/laps, porosities, grain flow, microstructure.
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.
Actual
forging
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
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.
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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).
FORGE offers the most unique
advantages for equipment
dimensioning and die life extension
Die crack
Hot forged steel yoke
Hirschvogel Umformtechnik GmbH
Actual
die
Simulation
result
120
110
100
90
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)
Uncoupled die stress analysis
allowing accurate stress
prediction. High stresses are
shown in red.
80
70
60
50
40
30
20
max. compressive force - measurement (MN)
max. compressive force - simulation (MN)
10
0
0
5
10
15
Blow No.
20
25
30
Closed correlation between
FORGE compressive
force prediction and
experiment.
Buderus Edelstahl GmbH
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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
initial billet heating and heat treatment.
Easy to setup tracking features of points or surfaces:
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).
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.
Prediction of temperature by induction heating
in the initial billet of an energy component.
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Pioneer and market leader
in automatic optimization
Extensive
Databases
FORGE includes an automatic optimization feature based on the MAES algorithm
(Meta-model Assisted Evolution Strategy). It can be coupled with some CAD packages.
Press and equipment kinematics available and filtered to comply
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
for forming and heat treatment
processes
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
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.
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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
Computation time
FASTER
FASTER
X1.2
FASTER
X2
FASTER
FORGE runs on various Windows and Linux platforms,
from standard workstations to multi-core High
Performance Computing clusters.
X3
X3.7
FASTER
4 cores
6 cores
12 cores
24 cores
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.
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.
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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
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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.com
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]
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
TRANSVALOR S.A.