Metal Forming Process: Open Die Forging Finite Element Simulation
FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization
Open die forging is used for large and critical products which cannot be forged by basic forging processes due to high deformation load or massive dimensions. Technological processes of open die forging are applied to produce individual, low-volume parts for die blocks, rings for further rolling, blanks of crankshafts for marine engines and other large parts requiring the characteristics and durability of a forging.
The shape of the workpiece does not result from the shape of the dies used, but from repeated local forming with geometrically simple dies that are typically moved relative to the workpiece. The shape of the workpiece is created incrementally, i.e. step by step. Usually, this is done when hot forging very large components for the machine and plant building industries, or for the densification of casted ingots. Open die forging is also used where shaping dies cannot be used for economic reasons. For special component shapes, techniques such as rotary swaging processes are used during cold forming of large production volumes.
When designing open die forging processes, the pass schedule, including possible intermediate heating, must be planned in such a way as to reach the required final geometry and the required material properties with as little effort as possible. High performance materials such as titanium and nickel based alloys can only be forged within a narrow temperature range.
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.
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
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Sheet Metal Forming: Advanced Finite Element Method for Industry Leading Simulation
Sheet metal components are highly suited to lightweight constructions. Different methods of sheet metal forming can be used depending on the geometry of the desired part. Based on the characteristics of each deformation process, the forming engineer can choose between: Deep drawing, ironing, punching, bending, stamping, and a variety of other manufacturing processes. Due to the geometric complexity of the parts being manufactured, additional multistage forming that combines different processes is frequently required within a phase of production.
Read more... Finite Element Simulation of Hot Forging
The recrystallization is responsible, through the complete reformation of the microstructure, possibly multiple times, for the formation of a relatively fine-grained microstructure. It exhibits the optimal combination of strength and ductility. This circumstance qualifies hot forging as one of the most important manufacturing processes for the production of highly stressed safety components.
Read more... Metal Forming Process: Open Die Forging Finite Element Simulation
When designing open die forging processes, the pass schedule, including possible intermediate heating, must be planned in such a way as to reach the required final geometry and the required material properties with as little effort as possible. High performance materials such as titanium and nickel based alloys can only be forged within a narrow temperature range.
Read more... Cold Forming Finite Element Simulation
Cold forming results in strain hardening, meaning both the strength and resistance to forming increase with ongoing deformation. Thus, cold formed components can withstand greater operational loads. At the same time, strain hardening results in reduced formability (ductility) of the material. If the component needs to be formed further, the strain hardening of the component has to be removed via recrystallization annealing. Cold forming and annealing are often part of a multi-stage process.
Read more... Finite Element Simulation of Roll Forming and Ring Rolling
Rolling is one of the most diverse forming processe in the forming technology. It is used for the production of semi-finished as well as finished products. Rolling processes are used in all areas of forming technology, both in hot forging and cold forming, and of course in sheet metal forming. There is a multitude of rolling processes. Some are named here: flat rolling, profile rolling, tube rolling, roll forming, forge rolling, cross-wedge rolling, wire rolling, and cross-row rolling.
Read more... Finite Element Simulation of Heat Treatment
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.
Read more... Hard Metal: Finite Element Simulation for Mechanical Properties on the Microstructural Level
Hard metals are functional materials with tuned performances arising from the composite microstructure. Understanding those composites on the microstructural level is key for material suppliers who need to innovate their products. Hard metals are two-phase materials with significantly differing mechanical properties on the microstructural level. Material properties are tuned by varying the content and microstructure of a hard inclusion phase. Key to further material development is to understand and optimize microstructural stresses in the composite.
Read more... FEA (Finite Element) Welding Simulation
RSW (Resistance Spot Welding), FSW (Friction Stir Welding), Pressure Welding, Arc, Electron and Laser Beam Welding
Enteknograte engineers simulate the Welding with innovative CAE and virtual prototyping available in the non-linear structural codes such as LS-DYNA, Ansys, Comsol, Simufact Welding, ESI SysWeld and ABAQUS. The Finite element analysis of welding include Arc Welding, laser Beam Welding, RSW, FSW and transfer the results of welding simulation for next simulation like NVH, Crash test, Tension, Compression and shear test and fatigue simulation.
Read more... Acoustics and Vibration Simulation
FEA & CFD for AeroAcoustics, VibroAcoustics and NVH Analysis in Automotive, Aerospace, Shipbuilding and Consumer Product Manufacturers.
The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.
Read more... Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation
Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.
Read more... Metal Forming Simulation
Sheet Metal Forming, Hot Forging, Cold Forming, Open Die Forging, Roll Forming, Extrusion and Heat Treatment with Ansys, Abaqus, LS-Dyna and Simufact
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. Metal Forming Simulation include Springback Compensation, Surface Defects, Cost Estimation and Phase Transformation in Sheet Metal, Hot Forge, Rolling, Extrusion, Open Die Forging and Heat Treatment Finite Element Analysis.
Read more... Finite Element Analysis of Durability and Fatigue Life
Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.
Read more... Additive Manufacturing and 3D Printing
FEA Based Design and Optimization with Simufact, Abaqus, ANSYS and MSC Apex for powder bed fusion (PBF), directed energy deposition (DED) and binder jetting processes
With additive manufacturing, the design is not constrained by traditional manufacturing requirements and specific number of design parameters. Nonparametric optimization with new technologies such as Artificial Intelligence in coupled with Finite Element method, can be used to produce functional designs with the least amount of material. Additive manufacturing simulations are key in assessing a finished part’s quality. Here at Eneteknograte, dependent of the problem detail, we use advanced tools such as MSC Apex Generative Design, Simufact Additive, Digimat, Abaqus and Ansys.
Read more... Heat Transfer and Thermal Analysis: Fluid-Structure Interaction with Coupled CFD and Finite Element Based Simulation
We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.
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