METAL FORMING SIMULATION TECHNOLOGY

Developing or modifying a metal forming process can involve significant tooling and capital cost. Finite element simulation technology reduces the financial risk of innovation by creating quantitative, in-depth studies of processes like hot, warm, and cold forming, trimming, shearing, rolling, bending and drawing. These studies then can be used to identify the best path forward.

We use DEFORM™ finite element simulation software to create a custom computer model of your existing or proposed process. Using this model, we explore how parameters and design choices affect material flow, tool load, stress, and defect formation. Armed with this knowledge, we help you move forward with confidence to address the challenges your business faces today and tomorrow.

ARE YOU LOOKING TO...
  • Increase profit margins?
  • Shorten development and launch timelines?
  • Improve defect and scrap rates?
  • Eliminate tooling failures and improve tool life?
  • Manage development costs to limit the risk of new and innovative ideas?

THE FREEDOM TO INNOVATE

DEFORM™ finite element simulations empower designers and engineers with the inside information they need to bring innovative designs to market faster and with less risk.

The ability to show how a process functions can pave the way to improved understanding, smoother projects, and happier customers. Simulation animations can be a significant asset when training your production staff to produce a new part or troubleshoot an existing process. They also can be used as a sales and marketing asset when talking with customers.

BENEFITS OF SIMULATION

TECHNICAL INSIGHTS

Predict and optimize process behavior before making changes on the shop floor:

• Identify forming loads to select the right press for the job
• Evaluate die fill and finished part dimensions
• Predict laps, folds, and cold-shuts
• Optimize material utilization to minimize flash and form closer to net shape
• Understand the root cause of tool failures and investigating alternative designs|
• Predict and reduce ductile fracture in cold forming
• Study grain flow

FINANCIAL BENEFITS

Simulation technology can facilitate:

• Faster turnaround for customer quotes
• More accurate timelines
• Lower scrap rates
• Fewer tool failures
• Reduced material costs

RISK MANAGEMENT

Process simulation gives design engineers the freedom to experiment with new processes and innovative ideas before taking those ideas to the shop floor. Your team can try various tool designs and progressions, identify the root causes of defects, and develop alternatives to eliminate those defects, all before you ever hit the first part.

Simulation also gives you the confidence to make crucial quote/no quote decisions. Modeling the interactions of process, materials, and tooling up front can help distinguish a difficult but potentially lucrative part from an overly complex, problematic part.

SEE HOW IT WORKS

Hammer Forging

Ring Rolling

Ring Rolling view 3

Thread Rolling

Billet Heatup

Thermal Expansion

Thermal Expansion 2

Furnace Operation view 1

Furnace Operation view 2

The applications are endless

Visit Scientific Forming Technologies, the creator of DEFORM™ finite element simulation software, to view videos of additional applications.

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