Finite Element Simulation of Roll Forming and Ring Rolling

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

Roll forming is a specific process within the metal forming industry. Characteristics of that method are high flexibility, low machine and tooling cost, and very good productivity. But like other metal forming methods, roll forming today is still a kind of “black art.” It is very difficult to understand what happens to the material during the forming process. Difficulties such as faults appearing and problems in setting up new roll sets on the mill are not uncommon. In a trial & error approach, one has to produce a whole roll set and do the machine set-up in order to find potential weaknesses in the roll forming process - a costly and time-consuming approach causing undesired machine downtimes.

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.

Ring Rolling

Ring rolling is a forming process for the production of rings. The ring rolling processes enable the production of rings with diameters ranging from ten centimeters to ten meters. Because of very high demands in accuracy and reliability required for production of ring and wheel rolling, efficient simulation is needed for detail investigation and verification in extremely high-performance finite element (FEA) simulation software.

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

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.

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.

WE WORK WITH YOU

We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.

Hot Forging Abaqus Ansys Msc MARC Simufact Autoform FTI Forming Nastran ls-dyna FEA Finite element 3

Metal Forming simulation damage limit diagram finite element Abaqus Ansys Msc Simufact Nastran ls-dyna FEA

Sheet Metal Forming Finite Element Method simulation Abaqus Ansys Msc Simufact Nastran ls-dyna FEA

Metal Forming Cold Abaqus Ansys Msc MARC Simufact Nastran ls-dyna FEA Finite element

Metal Forming simulation finite element Abaqus Ansys Msc Simufact Nastran ls-dyna FEA

Sheet Metal Forming Cold Metal Abaqus Ansys Msc Simufact Nastran ls-dyna FEA

Tube rolling Cross roll piercing Forming Metal Abaqus Ansys Msc Simufact Nastran Code aster ls-dyna FEA

Cold Forming Metal Abaqus Ansys Msc Simufact Nastran Code aster ls-dyna FEA

Hot Forging Abaqus Ansys Msc MARC Simufact Autoform FTI Forming Nastran ls-dyna FEA Finite element

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.