Metal Forming: Finite Element Simulation of Heat Treatment
FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization
Most of the technologies for the production of forged parts are required heat treatment after deformation to obtain the desired properties, both on the surface and through the entire volume of the detail. Heat treatment is a process or a combination of processes to treat metallic components. The components, commonly made of steel(s), are temporarily heated to specific temperatures.
Taking into account the rate of heating and cooling, the material properties of a component can be altered and improved. The presence of certain agents can lead to changes in the carbon or nitrogen content of the component. In all heat treatment processes, there are several decisive and important factors: Time (heating and holding time), temperature, atmosphere, and quenching or cooling conditions.
In principle, there are two kinds of heat treatment processes: processes resulting in a thorough change of the microstructure and processes that result in merely changing regions close to the surface of the component. Examples of the former would be thermal processes, such as annealing and hardening. Examples of the latter, thermochemical processes, would be diffusion and coating processes, such as carburization, case hardening, nitrating, boriding.
Simulating the process reduces the amount of experimentation required during process design and process optimization. It also helps to smooth trial runs and the prototyping process. Through simulation, typical mistakes such as too much or too little hardening, cracks from residual stress or too much distortion can be discovered before they are made.
Simulation Features:
- Prediction of phase transformations, phase composition of the workpiece, both at the deformation and heat treatment processes.
- Diffusion and martensitic phase transformations at cooling and heating of material while accounting the latent heat of phase transitions and volume changes in the transformation process.
- The heat treatment for simulation of different production processes: quenching, tempering, annealing etc.
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.
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.
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.
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