Full Representation of Shop Floor Forging Practice

Advantage by Increased Insight

TheThe Virtual Forging Shop Virtual Forging Shop

MSC.SuperForgeMSC.SuperForge

How is Full Representation Achieved?

• Comprehensive Material Data

• Realistic Press Characteristics

• Accounting for Friction

• Accounting for Temperature Effects

• Accounting for Elasticity

• Automatic/Manual Positioning of Work Piece

• Handling of Multi-Stage Processes

• Powerful CAD Interface

• Available in Database Form

• Select Material by “mouse-click”

• User-extendable Database

Comprehensive Material Data

• Material Data depends on

– work hardening

• temperature

– strain rate

Realistic Press Characteristics

• Most Press Types Available

• User-extendable Database

• Most Press Types Available

Friction

• Friction Influences:– load and energy requirements– metal flow– pressure distribution– die wear

• Friction Models– Coulomb friction– plastic shear friction– combination

• User-extendable Database

Temperature Effects• Needed to account for:

– proper metal flow – die chilling during forming– thermal stresses during cooling

• Heat Transfer between Work Piece and Dies

• Heat Transfer to Ambient

• Heat Conduction within both Work Piece and Dies

• Heat Generation due to Plastic Deformation

Elasticity Effects

• Needed to account for:– deviation from desired shape (tolerances)– thermal stresses– proper die loads (die overclosure)

• Elastic-plastic material model

Positioning of Work Piece

• Influences Metal Flow

• Automatic or Manual Positioning– sliding is accounted for !!

Accurate Workpiece Positioning

Multi-Stage Process Modeling

• Automatic Transfer of Material Properties between Stages– stress, strain, temperature

• Transport of Work Piece between:– furnace and dies– different dies

• Intermediate Heat Treatment• Handling by “mouse-click”

Powerful CAD Interface• CAD Transfer via STL (Standard Triangulation Language)

– standard format used in rapid prototyping techniques– commonly available in all CAD packages

• No ‘Finite Element’ Experience Required

• No Meshing

STL

• Why ? – enables precise filling of intricate die regions if metal

flows into such regions– no user intervention required

• Able to capture small intricate die details by using:

Resolution Enhancement Technology (RET)

Advantages of MSC.SuperForge

Industrial Examples

Forging of an Automotive Cap

pressure on tool

MSC.SuperForge

Selected Reference Accounts