Metal Forming Simulation: FEA Based Design and Optimization

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

Using advanced Metal Forming Simulation methodology and FEA tools such as Ansys, Simufact Forming, Autoform, FTI Forming, Ls-dyna and Abaqus for any bulk material forming deformation, combining with experience and development have made Enteknograte the most reliable consultant partner for large material deformation simulation.

FEA (Finite Element Analysis) in Metal Forming

Enteknograte engineers can simulate any manufacturing process for hot, warm, and cold forging, which includes but not limited to:

  • Closed die forging
  • Open die forging processes such as cogging, saddling, and other GFM processes 
  • Rolling for long products
  • Extrusion
  • Ring Rolling
  • Cross Wedge Rolling and Reducer Rolling for pre-forming
  • Cold forming
  • Sheet metal forming
Simultaneous engineering, which is carried out in an early stage of product design, allow us to easily take concepts and results from earlier phases and apply them later on in the product development process. When the feasibility check of a part is completed, we optimize the part design to achieve manufacturability. Our Simulation procedure include the most comprehensive solution for Heat Treatment simulation including phase transformation and thermal effect and Microstructure analysis.

Phase Transformation and Thermal Effect in Metal Forming

Including phase transformation and thermal effect enables us to realistically simulate the hot forming processes. These processes have become very important for the automotive industry in order to meet specific requirements regarding a higher level of crash safety and a reduction of overall weight. Detailed simulation of forming enable us to engineer components with high strength, challenging geometrical complexity and minimized springback effects. In addition, we can calculate the final part properties, such as strain-stress distributions as well as the distribution and local percentages of different material phases, such as austenite, ferrite, pearlite, bainite and martensite, including the resulting hardness distribution.

Enteknograte Simulation Features:
  • Realistic simulation of hot forming and quenching processes
  • Take into account phase transformation during quenching and thermal distortion after cooling.
  • Stamped parts with challenging geometrical complexity and minimized springback effects
  • Stamped parts engineered with targeted local strength properties
  • Improved crash simulation accuracy
  • Hot forming processes of ultra-high strength steels

Material Utilization

One of the most important issues in the industry is material utilization. As the price for both steel and aluminum continues to increase and more and more high-strength steels and lightweight materials are being used in the automotive industry, manufacturers continue to search for ways to optimize their use of materials. Enteknograte engineering team enable you to predict the potential of blank shape and nesting. We can efficiently calculate the optimal layout of the blank on the coil taking into consideration minimal material utilization.

Springback Compensation

Springback compensation is carried out during the process engineering phase to improve part and tool quality before the real tryout phase begins. As a result, the process layouts realized during the early planning phases are more reliable. Robust springback compensation enables us to minimize the risk of costly changes later on in the process due to the effects of springback.

Stamping Nakajima Test Forming Metal Abaqus Ansys Msc Simufact Nastran Code aster ls-dyna FEA
Stamping Nakajima Test

Tool Cost Estimation

We can help you to calculate tooling costs based on the defined production sequence. we can evaluate alternative production concepts and then rapidly identify the most cost-effective one. Our knowledge in FEA based design enable you to significantly reduce the time required for estimating tooling costs.

Process Planning

With special engineering methods, software and customizing ability of CAE software environment, enables us to rapidly generate and evaluate process plans. This feature enable us for increased planning reliability to meet quality and cost targets and enables the direct transfer of process plans to process engineering and validation in a short time.

Surface Defects Avoidance

Surface defects are small concave imperfections that can develop during forming on outer convex panels of automotive parts like doors. They occur during springback steps, after drawing in the vicinity of bending over a curved line and flanging/hemming in the vicinity of the upper corner of a door. They can alter significantly the final quality of the automobile and it is of primary importance to deal with them as early as possible in the design of the forming tools. As a result, during the product development process, much attention is paid to avoiding defects on surface appearance and the resulting surface quality. Enteknograte engineering team can evaluate surface defects in order to take steps to improve the surface quality with FEA based Design and optimization.