TRANSVALOR FORGE® simulation possibilities

FORGE®, a TRANSVALOR software 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 is a typical operation to get a well-balanced preform prior to forging All movements of the preform within the rolls can easily be described through a dedicated Multi-Pass Command File which allows defining the translation and rotation in between reducer rolling passes. Subsequent hammer forging operations are modelled showing contact evolution and potential underfilled areas. FORGE® validates the forging sequence solves shop-floor issues, and optimizes the forging yield of existing components. FORGE® predicts: the final dimensions of the component, defects like folds, underfillings, excess of materials, grain flow, microstructural evolution and press load. All kinds of forging equipments are available Easy following of segregations at the center of the billet. FORGE® locates areas with excess of material and consequently optimizes billet preform Cross wedge rolling (CWR) is a commonly used operation to produce preforms from cylindrical blocks or rods FORGE® simulates the metal flow occurring during CWR. It detects potential defects due to the Mannesman effect. FORGE® considers the real kinematics applied on the rolls. A rotational update scheme ensures volume conservation. Current results are easily chained with subsequent forming operations. FORGE® handles tooling analysis with multiple deformable bodies. Stress analysis provides guidance upon lifetime of forging dies. Shrink fit design of tooling for precision forging can be studied as well. Simulate trimming or piercing operations Get accurate prediction of trimming profile, forgings distortion and required press load. 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. Applications are for the aerospace industry (engine parts) the energy sector (windmills), or the automotive industry with bearings manufactured at ambient temperature. FORGE® simulates either rectangular or profiled rolled rings. Controls ring dimensions and prevents from typical uncertainties: For aerospace applications, FORGE® can simulate a large variety of parts made of nickel-based superalloys, titanium or aluminium grades with microstructure prediction capabilities. FORGE® embeds unique tracking features predicts surface folds, fibering, grain flow, underskin defects and much more. TRANSVALOR is the unique software editor in the field of forming process simulation to ensure the complete workflow from casting to forging. When using THERCAST® for ingot casting… …results at the end of casting process can be tracked during the subsequent forging operations with FORGE®. 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. Simulate continuous rolling, anticipate product imperfections: hot tearing, twisting, ripple effect. Predict deformation rate per pass inter-stand tension, loads and torques on rolling mill stands. Incremental forming process is a standard process which allows significant reduction of the press load. In-depth analysis can be conducted to follow the metal flow and to guarantee the complete filling of the inner teeth. FORGE® addresses major open-die forging processes cogging, becking, mandrel drawing, blooming. Simulation of the translation and rotation of the part, the displacements of the part at the end of one pass, the waiting time between each pass. The bi-mesh method grants important CPU time reduction. Coupling from THERCAST® casting software allows prediction of porosities closing and segregations localization. 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. Also applicable for: autenitization, aluminium quenching and aging, carburizing, annealing/tempering, induction hardening, nitriding. Flow forming or metal spinning processes make it possible to obtain cylindrical parts with complex shapes by reducing thicknesses. The challenges are linked to the location of the instant deformation zones and the high number of revolutions. Special numerical methods have been developed in FORGE® in order to reduce computation times yet granting high accuracy for the results. FORGE® uses ALE updating (Arbitrary Lagrangian-Eulerian method), a structured meshing adapted on the contact zones, Complex kinematics can be introduced, and elastic-plastic behavior laws corresponding to the aluminum alloy used. Control thickness and eccentricity variations during rolling of long products. 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. FORGE® addresses various fastening techniques: clinching, riveting, crimping with multiple materials. Test its resistance in-use. Contact algorithms allow multi-body calculation including every component of the assembly. For fastening simulations, FORGE® genuine elasto-plastic behavior calculates residual stresses as well as potential damage of the components. Simulation of high-quality fasteners: Real kinematics applied on the chaser dies, smart rotational update scheme ensures volume conservation.

One Reply to “TRANSVALOR FORGE® simulation possibilities”

  1. What I wouldn't have given for analysis of Crossroll forging designs in the 80's.  Fantastic software.

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