Fachartikel

Article published in "Finite Elements in Analysis and Design", Volume 84, July 2014, Pages 54–64

Authors:

M. Islam (a), A. Buijk (b), M. Rais-Rohani (a, c), K. Motoyama (a, c)

(a) Center for Advanced Vehicular Systems, Mississippi State University, MS 39762, USA
(b) Simufact-Americas LLC, Plymouth, MI 48170-4347, USA
(c) Department of Aerospace Engineering, Mississippi State University, MS 39762, USA

Abstract:
With the increasing pressure on the industry to save material, engineers are forced to come up with incremental forming processes like Radial Forming and Flow Forming. These processes are characterized by the excellent workpiece properties of the formed zones, the great variety geometries in net shape quality. It seems that the two processes are similar, but a closer examination of the stress state shows differences. This paper deals with the different processes of radial forging and flow forming and their stress states. The simulation of these processes with FEM models, carried out with the software SIMUFACT, allows a view into the forming zone. The investigations give an overview about the difference of the material flow during the forming process. These views guide the way to a useful industrial application of Radial Forming and Flow Forming.

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ScienceDirect

DER KALIBREUR, July 2013, Magazine 74/2013 (3,3 MB)

Authors:

Dr. Ralph Bernhardt, Simufact Engineering GmbH
Dr. Franz-Dieter Philipp, Mannstaedt GmbH

Abstract: 

Solving technological problems by means of the finite element method has meanwhile a tradition of some 60 years.
Whereas in the beginning, the development of complex models was reserved to an elite circle of highly specialized
computer experts, since the middle of the 1980s the FE method has become established as a tool for industrial scale
application also in the field of metal forming. The first applications more than 30 years ago were limited to 2D and rather simple geometries. For representing the basic possibilities and for validations, frequent use was made of symmetrical models from rolling, as that way comparisons with operating data could be rather easily accomplished.

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Artikel FASTENER TECHNOLOGY INTERNATIONAL, August 2012 (1,5 MB)

Author:

Mike Walker, Omni-Lite Industries

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Article released on occasion of the 4ª Conferência Internacional de Conformação de Chapas / 1º BrDDRG (936,8 KB)

Porto Alegre, RS - Brazil, 8-10 Oct, 2014

Authors:

Ibson Ivan Harter, João Henrique Corrêa de Souza - Bruning Tecnometal Ltda, Brazil
Arjaan Buijk, Zach Pursell - Simufact-Americas LLC

Abstract:

A special meshing technology was implemented in Simufact.forming to create an optimized HEX mesh for thick sheets. This innovative technology enabled efficient non-linear finite element simulations of large, industrial sheet metal forming processes using 3D Solid elements.To validate for what type of processes it is beneficial to use 3D Solid elements, and to determine the optimal modeling parameters, a detailed study was performed at Bruning Tecnometal Ltda., to compare the different simulation methodologies with experimental data.

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Article FOCUS, June 2013, Issue 2/2013 (951,6 KB)

Authors:

Dr. Gabriel Mc Bain - Simufact India Pvt. Ltd., Bangalore, India
Dr. Hendrik Schafstall - Simufact Engineering GmbH, Hamburg, Germany
Raman Gupta - Kadkraft Systems Pvt. Ltd., Chandigarh, India

Abstract:

Die life is a major concern when for the forging industry. Fig. 1
shows the major failure mechanisms of forging dies of which
cracking is the most dominating failure mechanism followed
by wear.

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Article published on occasion of the IDDRG conference in Mumbai, India
November 25-29, 2012 (2,6 MB)

Authors:

Dr. Ingo Neubauer, Dr. Gabriel Mc Bain, Simufact Engineering GmbH

Abstract:

The increasing demand for lightweight structural components with optimized strength to weight ratios requires ever more complex sheet metal components. These are increasingly substituting components produced with simple manufacturing processes. The corresponding manufacturing technique needed to produce these parts is characterized by its high complexity. The high time and costs to produce such tools for commercially successful products, requires a reliable process design. As a consequence, the metal forming simulation has become an essential tool for these processes. The simulation of sheet metal forming processes with stresses predominantly taking place in the sheet plane causing plane stress conditions, has long been state of the art.

However, the greater the ratios between the wall-thickness and the curvature radii of the manufactured geometries become, the stronger the stress state resulting from the triaxiality effects leads to errors in the simulation. To correct for this, it is necessary to rely on simulation models that in the past were exclusively used for bulk metal forming. Simufact.foming is a sophisticated simulation tool providing simulation models for both, bulk and sheet metal forming processes always considering the triaxiality of the stress state with dedicated meshing and remeshing techniques for bulk and sheet metal forming processes. Accordingly, this paper presents state of the art simulation solutions and corresponding shop floor examples that meet these technological requirements.

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Article published in FORGING magazine, July/August 2011 (1,7 MB)

Author:

Arjaan Buijk, Simufact Engineering GmbH

A special module for ring-rolling simulation has matured and achieved acceptance by the industry, and new developments lie ahead.

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Article published in FORGING magazine, January/February 2010 (1,2 MB)

Abstract:

ABP Induction and Simufact research, develop and present new technology for simulating the effects of billet heating
in the hot forging process.

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Article published in FORGING magazine, 08/2010 (2,0 MB)

Authors:

Jürgen Schüler, Neumayer Tekfor Group
Michael Wohlmuth, simufact engineering gmbh

Abstract:

Tekfor cologne deploys Simufact.forming to achieve a quality, cost-efficient forming simulation.

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Article published in the INTERNATIONAL SHEET METAL REVIEW
February 2012 (754,9 KB)

Welding simulation supports process understanding in sheet metal forming, says Dr. Hendrik Schafstall.

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Article published on occasion of the 18^th International Forgemasters Meeting in Pittsburgh, PA (USA), September 12-15, 2011 (1,3 MB)

Authors:

E. Oka, R. Higashi, T. Nomiyama, Mitsubishi Nagasaki Machinery Mfg. Co., Ltd., Japan

Abstract:

In recent years, the demands for the near-net-shaped rings, nearer to the product ring shapes, are increasing, in response to save energy and to improve cost-competitiveness. MNM focused on the vertical ring rolling mills which are used in some of the bearing manufacturers in Japan, and had completed the fully-automated vertical ring rolling mill for rolling profiled rings. This VRRM is intorduced.

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Article published in "Advanced Materials Research", Volume 1018, September 2014, Pages 309-316

Authors:

Kolja Andreas, Christoph Kiener, Ulf Engel, Marion Merklein

Available for purchase via Scientific.Net

In cold forging, the forming tool takes a key role as it determines accuracy and efficiency of forming process. The present study focuses on the FE based analysis of the influence of die material, interference within prestressing and die splitting on the stress state in and the elastic behaviour of the forming tool. The results reveal a great influence of the workpiece material and the tool layout on the outcome of the forming process and the corresponding tool stresses.

Scientific.Net

Arcticle published in "Journal of Materials Processing Technology", Volume 219, May 2015, Pages 286–294

Authors:

Stefan Kleditzsch, Birgit Awiszus, Michael Lätzer, Erhard Leidich

Available for purchase via ScienceDirect

This paper describes a verified numerical investigation of the joining process and the axial strength of steel/aluminum knurled interference fits (100Cr6/AlMgSi1). Knurled interference fits have huge potential, as demonstrated by their increasing industrial use. However, as is characteristic of state of the art of knurled interference fits, current research lacks generality and makes comparison difficult between results, especially in relation to geometry-, material- and load-specific results. The work in this paper provides detailed investigation results for the influence of shaft-chamfer angle, hub-diameter ratio and geometric interference on knurled interference fits. This includes the type of joining process as well as joining force and axial strength. The joining process is essential for axial strength as well as for the transmission behavior of the connection. Finally, a new approach for the analytical computation of the joining force is presented.

ScienceDirect

Authors:

Umut İncea, Norm Fasteners Cooperation 35620 Çiğli, İzmir, Turkey
Mustafa Güdenb, Department of Mechanical Engineering and Dynamic Testing and Modeling Laboratory, Izmir Institute of Technology, Gülbahçe, Urla, Izmir, Turkey

This study reports two case studies of the cold forging simulation in fastener production.

Abstract:

The use of finite element method increasingly as tool in metal forming industry result in cost reduction, time saving and improvement in product quality. The simulation software in the cold forging industry show material flow, capture the defects and allow to determine the process parameters such as pres forces, die stresses, predict the tool life and fracture and calculate residual stresses. The present study reports two case studies of the cold forging simulation in fastener production.

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Article published in: Laser Technik Journal - February 2015

Authors:

Raphael Thater, Philipp Wiethop and Michael Rethmeier

In this article, numerical welding simulation is used to deal with thhe challenge to find the optimal set-up within his large parameter space.

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Article published in the INTERNATIONAL SHEET METAL REVIEW 
November 2015 (413 KB)

Interview with CEO Michael Wohlmuth at the Blechexpo 2015

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This article has been released in the FORGE magazine

Open-die forgers use computer simulations to maximize their material yield, design dies, establish process procedures and more. Using simulation technology, forgers wield a powerful tool that helps them make high-quality parts efficiently and without trial-and-error.

Author:

Arjaan Buijk

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This article has been released in the German professional magazine Wire 2/ 2016.

FEM simulation programs currently constitute a powerful and widely used instrument for the design of processing stages, the optimisation of material flows and forecasting of die wear. They are used as standard in many cold- and hot-forming plants for the design and configurations of dies. 

Author:

Mr. Gabriel Mc Bain, Simufact Engineering GmbH

Mr. Bernhard Toennesmann, Möhling GmbH & Co. KG

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Brazing is a common technology for joining of aluminum components. Besides conventional methods, laser brazing is about to be established as a standard brazing technology. It offers several advantages compared to welding, e.g. less thermal induced stresses and less rework of the seam surface.

Article published in: DVS Berichte, 9th. Int. Congress Aluminium Brazing

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Author: 

Khazan P. (Hamburg / Germany), simufact engineering

Radel. T. (Bremen / Germany)

Woizeschke, P. (Bremen / Germany)

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Bulk-metal forming processes contribute to the efficient, sustainable use of resources through their preceise design and the implementation of process combinations. The design of process chains is used to achieve targeted from material characteristics and is based on the premise of fast and flexible production - with a simultaneous reduction of costs. 

Article published in: FORGEmag, August 2016

Authors:

Dirk Klug, Schuler Pressen GmbH, Germany
Hendrik Schafstall, Simufact Engineering GmbH, Germany
Markus Bergmann, Fraunhofer IWU, Germany

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The trend in the automotive and aircraft industry is moving towards customized designs by using compound structures, which provide an enlarged potential for weight and cost savings. Particularly, thermal joined lightweight structures made of aluminium alloys are characterized by moderate material and processing costs.

Authors: B. Striewe, J. Seiderer, A. von Hehl, A. Repenning, P. Khazan and H. Schafstall

Article published in: Materials Science & Engineering Technology, Vol. 47 - No. 11 - November 2016, Wiley-VCH

Available for purchase via: Wiley Online Library

With increasing pressure to reduce weight of vehicles to meet demanding pollution norms, automotive companies across the world are exploring the possibility of use of high specific strength materials which can reduce the weight of vehicles by maintaining the strength & safety aspects of vehicles. 

Article published in: TRB Technical Reference Bullentin, Symposium on International Automotive Technology 2017

Authors:
Vinand Arabale, Simufact Engineering - India
Dr. Ralph Bernhardt, Simufact Engineering GmbH

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New Forming Software Offers Improved Operation & Covers Additional Processes

Author:
Volker Mensing, Simufact Engineering GmbH

Article published in: Wire & Cable Technology International / March 2017

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Although they have already been in use for decades, welding processes are still some of the most mathematically complex methods that can be described. The reason for this is the localised heat input, with its very short heating and cooling periods and the related effects on the mechanical and metallurgical properties in the fusion zone. Thanks to the availability of high-power computers, numerical computer programs make it possible for the thermo-mechanical properties of welded structures to be reproduced in numerical simulations.

Article published in: ATZoffhighway worldwide, Issue 1/2017

Autors:
Dr.-Ing. Marius Gatzen, Simufact Engineering GmbH
Jochen Seifert, Edag Engineering Schweiz GmbH

Available for purchase via Springer Professional

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"Simufact from Hamburg/Germany, an MSC Software company, brings to market "Simufact Welding 7", the next version of its solution for the simulation of welding processes. Functional novelties such as solid-shell elements, simplified calculation methods for resistance spot welding processes and more flexible consideration of clamping concepts: "Simufact Welding 7" promises shorter processing times, more accurate results, and a more intuitive operational use of the software."

Article published in: Welding and Cutting 16 (2017) No. 5, p. 290

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Chip formation simulations require either sophisticated material based element removal or deactivation routines, or a powerful remeshing
procedure. Therefore the accuracy of all chip formation simulations significantly depends on the FEM-software as well as the material data.
Over the course of the past years, a few select commercial programs became the pre-eminent choice for chip formation simulations. In this
work, the software simufact.forming, which is not one of those few programs widely in use, has been employed for 2D and 3D chip formation
simulations. Orthogonal cutting experiments with AISI4140 were conducted and subsequently modeled, including the cutting edge

Article published in: 16th CIRP Conference on Modelling of Machining Operations, June 2017

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Sheet-bulk metal forming is an innovative method for the manufacturing of functional components by applying bulk metal forming processes or combined sheet and bulk metal forming processes to sheet metal. The investigated process combines deep drawing and upsetting. Occurring 2D and 3D stress and strain states lead to challenges regarding the material flow control during the forming process to ensure a high die filling and accurate part geometry.

Authors: Robert Schultea , Philipp Hildenbranda, Michael Lechnera and Marion Merkleina

Article published in: Procedia Manufacuring, Juli 2017

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The predictive value of process and product modeling by finite-element simulations has helped in the cold forging of fasteners. In this case, the punch used in a whell-hot forging was reconsidered and redesigned to eliminate the punch "sticking" in the hollow section of the forging.

Authors: Cenk Kilicasalan, Tayfur Yavuzbarut, Unmut Ince - Norm Civata San. ve Tic A.S. (Norm Fasteners Co.) Turkey

Article published in: FORGE magazine, August 2017

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In this study, manufacturability of Ø23x36 aluminum bushes with EN AW 6082-AlSi1MgMn aluminum alloy was investigated. Two different pretreated EN AW 6082 alloys, H13 (strain-hardened) and T4 (solution annealing and naturally aged) were used in the present study and cold forging performance of the alloys was evaluated comparatively. Compression tests were carried out at different temperatures and strain rates to model the flow stress of the alloys.

Authors: Buğra Karahan, Umut İnce, Sezgin Yurtdaş, Emrah Kılınçdemir, Fuat Can Ağarer,Cenk Kılıçaslan

Article published in: Acedemic Platform, September 2017

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Due to increasing product requirements the numerical simulation has become a powerful tool for the effective and efficient design of individual process steps as well as entire process chains. In order to model hot forging processes with finite element based numerical methods realistic models are required which consider the detailed mathematical description of the material behaviour during the forging process, the surface phenomena at die and workpiece as well as machine kinematics.

Authors: B.-A. Behrensa, R. Kawallab, B. Awiszusc, A. Bouguechaa, M. Ullmannb, M. Grafc

Article published in: Procedia Engineering, September 2017

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An increasing demand on highly-integrated high-strength lightweight components, especially in the automotive industry, motivates the need for the development of the new class of manufacturing processes sheet-bulk metal forming (SBMF). The use of SBMF for producing those components leads to many challenges. This is due to the fact that the processes are characterized by a successive and/or simultaneous occurrence of different load conditions regarding stress and
strain states.These conditions influence the material flow and thus the geometrical accuracy of the produced parts. To improve the product quality, methods to control the material flow are needed. 

Authors: Maria Löfflera, Ulf Engela, Kolja Andreasa, Marion Merkleina

Article published in: 13th International Conference on Shot Peening, September 2017

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In order to analyze the performance of wire and arc additive manufacturing for 5CrNiMo hot forging die remanufacturing, the FEM numerical model of multi-layer and multi-pass welding was built. The thermal distribution and cycle in weld beads were investigated, and the simulation results conformed to the experimental measurements well. Then the microstructure and microhardness in different layers and the heat affected zone in the substrate was analyzed after the experiment of weld overlaying, and the influence of the thermal cycle on the metallurgical characteristics was also discussed. 

Authors: Zeqi Hua, Xunpeng Qina, Tan Shaoa,

Article published in: Procedia engineering, September 2017

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back behavior is one of the most important factors on the discrepancy, in not only sheet metal forming but also cold forging processes. Spring back behavior is one of the most important factors on the discrepancy, in not only sheet metal forming but also cold forging process. For cold forging process, it is difficult to observe the change in geometry of forgings before and after release of tools/dies, since the workpiece during forging is covered by tools/dies in most cases.

Authors: Shinobu Naritaa, Kunio Hayakawab, Yoshihiro Kubotab,
Takafumi Haradab, Takeshi Uemoric

Article published in: Procedia engineering, September 2017

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Resource-efficient development of thermally highly resistant engine components of hybrid metal composites - experiments and numerical analysis

Authors: Dirk Landgrebe, Lutz Krüger, Nadine Schubert, Eric Jentsch, Tim Lehnert

Article published in: Procedia Engineering, November 2017 

One remark in our own interest: With the release of Simufact Forming 15 users can simulate inductive heating. 

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Care should be taken in modeling the cold forging of fasteners through computer simulations. It has been shown that pre-forming operations have significant effect on predicting cracking based on mathematical damage models. Pre-forming operations such as wire drawing and bar cropping should be included in the simulation model for highest accuracy and best predictive results. 

Authors: Cenk Kilicasalan - Norm Civata San. ve Tic A.S. (Norm Fasteners Co.) Turkey

Article published in: FORGE magazine, December 2017

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Wetting steel surfaces with liquid aluminum without the use of flux can be enabled by the presence of a zinc-coating. The mechanisms behind this effect are not yet fully understood. Research results on single aluminum droplets falling on commercial galvanized steel substrates revealed the good wetting capability of zinc coatings independently from the coating type. The final wetting angle and length are apparently linked to the time where zinc is liquefied during its contact with the overheated aluminum melt. 

Authors: Marius Gatzen, Peer Woizeschke, Tim Radel, Claus Thomy and Frank Vollertsen 

Article published in: MDPI, December 2017

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Тhis paper presents results obtained in the course of development of new calibration rolls for rolling round steel № 40 in 320 JSC „SSGPO“ mill. There is an untapped potential of the rolling mill capacity during the production of round barswith a diameter of 40 mm from initial 120 mm × 120 mm billets. The solution of this problem refers to the mill translation to production of round steel with a diameter of 40 mm from initial 150 mm × 150 mm billets.  

Authors: Abdrakhman B. Naizabekov, Bereke S. Mukhametkaliev, Sergey N. Lezhnev,
Evgeniy A. Panin, Evgeniy V. Andreev 

Article published in: Naizabekov, Bereke S. Mukhametkaliev, Sergey N. Le, January 2018

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Simufact's Micahel Wohlmuth and Michael Tran describe LightHinge+, a co-engineering project that used the extended possibilities of additive production to develop a lightweight solution with fewer components and simpler assembly. 

Article published in: ams magazine, January-February 2018

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Simufact is one of the pioneers in the exciting field of simulation for metallic additive manufacturing. Hendrik Schafstall,
General Manager & CTO with the vendor, explains state-of-the-art applications.

Interview with Dr. Hendrik Schaftstall, Managing Director & CTO, simufact engineering gmbh

Published in: d1g1tal AGENDA, 1-2018

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Residual stresses are inherently introduced to forged products during their deformation.
These stresses influence the integrity of load-bearing parts. Their effects depend on their nature
(tensile or compressive), location and magnitude. Tensile residual stresses’ integrity can be very
detrimental, particularly for products used in the as-forged condition. In contrast, compressive
residual stresses can be a lifesaver, if tailored appropriately. Hence, numerical and experimental
methods should be carried out to characterize the residual stresses, and they should be taken into
account for forged products to prevent premature failure and to improve service life.

Authors: M. Burak Toparli, Sezgin Yurtdas¸, Emrah Kılınçdemir, Barıs¸ Tanrıkulu – NORM Group; Izmir, Turkey

Article published in: FORGEmag - April 2018

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The paper addresses the problem of material fracture in cross rolling processes. A new test based on rotary compression for determining limit values of the damage function after the Cockroft-Latham criterion is proposed. A FEM analysis is performed to determine the stress and strain states in a workpiece subjected to this test. The numerical results demonstrate that the axial region of the workpiece is characterized by the presence of alternating tensile and compressive stresses conducive to fracture. The distribution of the Cockroft-Latham integral in the axial region of the workpiece is determined.

Authors: Zbigniew Pater, Patrycja Walczuk, Konrad Lis, Łukasz Wójcik

Article published in: Advances in Science and Technology Research Journal - June 2018

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Article describes the adoption of the Taguchi method in selective laser melting process of sector of combustion chamber by numerical and natural experiments for achieving minimum temperature deformation. The aim was to produce a quality part with minimum amount of numeric experiments. For the study, the following optimization parameters
(independent factors) were chosen: the laser beam power and velocity; two factors for compensating the effect of the residual thermal stresses: the scale factor of the preliminary correction of the part geometry and the number of additional reinforcing elements. 

Authors: A I Khaimovich, I S Stepanenko and V G Smelov 

Article published in: IOP Publishing - September 2018

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Edag, voestalpine and simufact have developed the additively manufactured LightHinge+ engine hood hinge. The worthwile result: As well as being half the weight of conventional designs, it also incorporates a pedestrian protection function. The component can be manufactured without tools, is optimized for warpage and requires only minimum post-processing.

Authors: Dr.-Ing. Martin Hillebrecht, Edag Engineering GmbH, Sebastian Flügel, Edag Engineering Gmbh, Dr.-Ing. Eric Klemp, voestalpine Additive Manufacturing Center GmbH and Dr.-Ing. Patrick Mehmert, simufact engineering gmbh

Published in: 120 Years of ATZ - Anniversary edition 2018

The article is available online via Springer Fachmedien

The work represents the approaches for designing the quality system for gas turbines
engines parts additive manufacturing. For gas turbines engines applications, the quality
parameters obtained by the selective laser melting are insufficient and require the subsequent
surface treatment.

Authors: V V Kokareva,  V G Smelov1, A V Agapovichev, A V Sotov, V S Sufiiarov,

Published in: IOP Publishing - November 2018

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A chained forming–welding process is to be investigated and analyzed using experimental verification and numerical simulation in which the material and mechanical properties are fully transferred between processes. The investigated part is in the form of a tube with dimension of 300 mm (l) × 20 mm (OD) × 1.5 mm (t) made of a low carbon steel material DC04 commonly used for
automotive parts and support structure.

Authors: Alexander Bauer, Yupiter H. P. Manurung, Joeran Sprungk, Marcel Graf, Birgit Awiszus, Keval Prajadhiana

Published in: The International Journal of Advanced Manufacturing Technology - October 2018

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