COLDFORM 2D & 3D METAL COLD FORMING SIMULATION SOFTWARE MATERIAL FORMING SIMULATION

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Charlene Skinner
5 years ago
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1 COLDFORM 2D & 3D METAL COLD FORMING SIMULATION SOFTWARE MATERIAL FORMING SIMULATION

2 2

3 A very broad application scope COLDFORM meets the needs of industrialists in many fields: design and manufacture of parts formed from sheets ranging

; design and manufacture of motor parts: shafts, gears, rings produced by ring rolling, cold-formed parts.

of innovative or complex products: lifting technological barriers to innovation, reducing design costs, reducing development costs, making products more

During the production phase, to optimize the various forging steps and improve manufacturing processes: reducing prototyping and workshop testing

During the negotiation phase, thanks to production cost control and improved schedule reliability: considerably shortening the design phase, reducing

3 3 A very broad application scope COLDFORM meets the needs of industrialists in many fields: design and manufacture of parts formed from sheets ranging in thickness from moderate to high (clockmaking, precision mechanics, etc.); design and manufacture of assemblies: screws, nuts, bolts, washers, etc.; design and manufacture of motor parts: shafts, gears, rings produced by ring rolling, cold-formed parts. Significant cost and productivity gains The benefits of COLDFORM can be observed at all steps in your activity During the R&D phase, for the development of innovative or complex products: lifting technological barriers to innovation, reducing design costs, reducing development costs, making products more reliable and reducing technical risks, building your company s knowledge and expertise. During the production phase, to optimize the various forging steps and improve manufacturing processes: reducing prototyping and workshop testing related costs, reducing the quantities of materials used, optimizing production processes, extending die service life. During the negotiation phase, thanks to production cost control and improved schedule reliability: considerably shortening the design phase, reducing material costs, reducing time-to-market, Simulation of the thread rolling process and von Mises stress estimates. This simulation is part of the complete screw forging calculation, meaning that the calculation of residual stress takes into account the previous forging steps. Riveting: residual stress prediction

dimensions of the definitive parts, taking spring-back into consideration; material yield throughout the forming sequence; possible underfill and fold;

damage and rupture criteria; residual stress distribution; etc.

An exhaustive database and a plethora of models COLDFORM contains a rich materials database: more than 200 steel, aluminium and brass references, ability

4 4 Rapid computation for precise results COLDFORM allows you to optimize your forming operations and to precisely predict: the exact geometry and dimensions of the definitive parts, taking spring-back into consideration; material yield throughout the forming sequence; possible underfill and fold; fibering and stress distribution; marking and monitoring of specific surfaces, such as cutting surfaces, from the initial billet to the final shape; damage and rupture criteria; residual stress distribution; etc. but also material displacement, plastic deformation, temperature and all other user-defined variables. An exhaustive database and a plethora of models COLDFORM contains a rich materials database: more than 200 steel, aluminium and brass references, ability to create material data from the mechanical properties provided by the manufacturer (yield strength, tensile strength and elongation at break). The software provides models for materials with standard and anisotropic behavior, with a vast range of lubrication conditions and the ability to define several friction conditions for the same die. The 4 steps in the forging sequence for a standard automotive sector part. (Hatebur Umformmaschinen AG,

5 Bevel gear forging simulation: contact analysis at

COLDFORM : Closed die forming Stamping Cutting,

Extrusion process Riveting and crimping process

forming of an automotive part on a three-pass machine,

(K-Won, Korea) Stress distribution in a 7-component

Stress analysis is performed on all 7 components.

5 5 Bevel gear forging simulation: contact analysis at various steps in the process (contact surfaces are shown in blue). Some examples of cold forming processes simulated by COLDFORM : Closed die forming Stamping Cutting, shearing and piercing Orbital forging Hydro forming Extrusion process Riveting and crimping process Incremental forging Thread rolling Ring rolling Cold forming of an automotive part on a three-pass machine, taking press stiffness into account. (K-Won, Korea) Stress distribution in a 7-component assembly. Stress analysis is performed on all 7 components. Stamping a 115 mm high and 0.8 mm thick aluminium part. (K-Won, Korea) Final geometry of the stamped part. Only a suitable mesh can enable the crumpling of the definitive shape to be accurately represented.

choices by precisely determining the press required to form your parts.

mills. COLDFORM allows you to analyze die strength in order to extend their service life.

Moreover, COLDFORM is capable of performing coupled part/die computations, giving extremely precise results.

6 6 Validate your equipment choices, extend die service life and reduce die costs COLDFORM allows you to validate your equipment choices by precisely determining the press required to form your parts. Its database contains models for: mechanical presses, hydraulic presses, knuckle presses, orbital forging presses, circular rolling mills. COLDFORM allows you to analyze die strength in order to extend their service life. The software can compute stress distribution within the die, along with deformations, wear, temperatures and damage at any time during the process. COLDFORM can perform rapid analyses consisting in applying the stresses obtained during forming process calculation to the die. Moreover, COLDFORM is capable of performing coupled part/die computations, giving extremely precise results. It is also easy to define prestressed dies and to study the effects of interference fit. Prediction of press force required to forge a screw using a mechanical press Stress distribution within the top die used to forge a bevel gear Analysis of the 7 dies used to forge an automotive part. This calculation takes tool interference fit into account. von Mises stress is represented for all dies. COLDFORM, the answer: > to your quality demands, > to your cost control requirements, > for reducing your lead times.

7 COLDFORM application example The following part is produced

COLDFORM simulates and chains each step in the process in

The simulation precisely computes part changes during the

The following illustration shows a comparison between the

In addition to predicting the overall shape, COLDFORM also

Elliptical contact area S-shaped line An initial examination

easily identified, along with all other geometric

The study of the second end of part shows the extrusion

7 7 COLDFORM application example The following part is produced in four steps, with annealing operations. COLDFORM simulates and chains each step in the process in order to study the complete forging sequence. The simulation precisely computes part changes during the forming steps. The following illustration shows a comparison between the actual part and the simulation result. In addition to predicting the overall shape, COLDFORM also reveals any local defects. Elliptical contact area S-shaped line An initial examination of the results enables contact and non-contact zones to be easily identified, along with all other geometric imperfections. The study of the second end of part shows the extrusion length differences and defects in the orientation of some surfaces. Thus, the preliminary study of the forging sequence using predictive simulation software such as COLDFORM allows you to anticipate defects and to optimize a forming sequence prior to conducting production line tests.

8 A premium service based on 30 years of experience TRANSVALOR is a world leader for simulation software in the field of material forming. Thanks to its continuous R&D policy, TRANSVALOR software remains constantly at the cutting edge of technology. More than 500 customers worldwide, including major players in the automotive, aeronautics and energy industries, along with several prestigious universities, trust TRANSVALOR and its software, thus guaranteeing their efficiency and reliability. Transvalor is also a team of experts dedicated to your simulations Your requirements correctly understood Unique means available to you Through exchanges with your specialists, we are able to determine your numerical simulation requirements in order to precisely determine the service that we offer. Our offer will closely meet your needs in terms of lead times, budget and expected results. TRANSVALOR S.A. Results analyzed and interpreted Throughout the study phase, we keep you informed of progress. Upon completion of the study, we present you with our main conclusions during a Web conference. Upon request, the results files, along with any means required to analyze them, can also be provided. Parc de Haute Technologie 694, avenue du Dr. Maurice Donat Mougins Cedex - France Phone: +33 (0) Fax: +33 (0) services@transvalor.com In order to create your service, we provide: TRANSVALOR s expertise in simulation the most recent software versions latest-generation computational resources Advice and training TRANSVALOR also proposes assistance days to ensure that you are fully abreast of all aspect involved in your study. Tailored topical training may be provided on your premises, on TRANSVALOR s premises or by Web conference. 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. COLDFORM is a registred trademarks of TRANSVALOR S.A. - non-contractual Document - Design Emmanuel Briot - PrintCentre

OPTIMIZE YOUR INJECTION PROCESS

FOR PLASTICS MOLDING PROCESSES OPTIMIZE YOUR INJECTION PROCESS MATERIAL FORMING SIMULATION 2 www.transvalor.com Boost your R&D and Reduce Production Costs SHORTEN CYCLE TIME Use REM3D to determine optimum