Fachartikel
Fachwissen kompakt
Hier finden Sie Fachwissen zu den Themen Umform- und Schweißsimulation sowie zur additiven Fertigung, kompakt präsentiert in einer Auswahl von Fachartikeln aus Fachzeitschriften und wissenschaftlichen Publikationen - von und über Simufact.
Fachartikel deutsch
Fachartikel BLECH ROHRE PROFILE, Juni 2013, Heft 3/2012 (1,5 MB)
Autor:
Dr. Ingo Neubauer, Simufact Engineering GmbH
Fachartikel DER KALIBREUR, Juli 2013, Heft 74/2013 (3,3 MB)
Autoren:
Dr. Ralph Bernhardt, Simufact Engineering GmbH
Dr. Franz-Dieter Philipp, Mannstaedt GmbH
Fachartikel BÄNDER BLECHE ROHRE, Oktober 2012, Heft 10/2012 (50,3 KB)
Fachartikel BLECH, Juni 2012, Heft 4/2012 (435,3 KB)
Fachartikel DRAHT, Heft 2/2010 (3,4 MB)
Autoren:
Dr. Hendrik Schafstall, Michael Wohlmuth, simufact engineering gmbh
Hilmar Gensert, Sieber Forming Solutions
Fachartikel FOCUS, Juni 2013, Heft 2/2013 (1,5 MB)
Autoren:
Dr. Gabriel Mc Bain - Simufact India Pvt. Ltd., Bangalore, Indien
Dr. Hendrik Schafstall - simufact engineering gmbh, Hamburg, Deutschland
Raman Gupta - Kadkraft Systems Pvt. Ltd., Chandigarh, Indien
Dieser Artikel ist in der Fachzeitschrift FOCUS, dem Organ des indischen Schmiedeverbands AIFI, im Original in englischer Sprache erschienen.
Fachartikel STAHL UND EISEN, Oktober 2012, Heft 10/2012 (684,4 KB)
Autoren:
Dr. Hendrik Schafstall, Dr. Gabriel Mc Bain, Dr. Christian Barth,
Simufact Engineering GmbH, Hamburg;
Dipl. Ing. Jan Terhaar, M. Sc. Jan Jarolimeck,
Saarschmiede GmbH Freiformschmiede, Völklingen
Fachartikel SCHMIEDE JOURNAL, März 2010 (196,5 KB)
Autoren:
Dipl.-Ing. Andreas Hagen, Dr. Hendrik Schafstall, Simufact Engineering GmbH, Hamburg
Fachartikel UMFORMTECHNIK, Oktober 2014, Heft 4/2014 (851 KB)
Autoren:
Dr. Gabriel Mc Bain, Michael Wohlmuth, simufact engineering gmbh, Hamburg
Stefan Calmano, Institut für Produktionstechnik und Umformmaschinen der TU Darmstadt
Jörg Stahlmann, Consenses GmbH
Artikel BLECH ROHRE PROFILE, Oktober 2013, Heft 5/2013 (1,6 MB)
Das Simulationsprogramm Simufact.welding ebnet den Weg für eine breite Anwendung von Simulationstechnologie zur Optimierung von industriellen Schweißverfahren.
Fachartikel SCHMIEDE JOURNAL, September 2013 (991,4 KB)
Autoren:
Dr.-Ing. Dirk Klug, Schuler, Waghäusel
Dr.-Ing. Hendrik Schafstall, simufact engineering gmbh, Hamburg
Dipl.-Ing. Markus Bergmann, Fraunhofer Institut IWU, Chemnitz
Artikel DRAHT, Juni 2011, Heft 6/11 (321,1 KB)
Autoren:
Guido Berti, Manuel Monti, beide Università degli Studi di Padova
Nicht nur bei Blech und Antriebsstrang ist Massenminderung angezeigt. In jedem Pkw stecken rund 4000 Federn. Da ist reichlich Sparpotenzial vorhanden. FEM-Analysen auf Basis von Simufact.forming helfen dabei, die Drahtdurchmesser von Schraubenfedern ohne Verlust an Performance zu optimieren. Die Universität Padua hat’s vorgerechnet.
Artikel ELEKTROWÄRME INTERNATIONAL, März 2010, Heft 1/2010 (971,2 KB)
Autoren:
Dr. Hendrik Schafstall, Michael Wohlmuth, Simufact Engineering GmbH, Hamburg
Artikel BLECHNET, November 2013, Heft 6/2013 (435,3 KB)
Autor:
Dr. Hendrik Schafstall, Simufact Engineering GmbH, Hamburg
In Fertigungsbetrieben beruht die Auslegung und Durchführung des Schweißens von Bauteilen oft auf empirischen Untersuchungen und Erfahrungen. Eine gezielte Optimierung und Anpassung des Fertigungsverfahrens ist nur mit hohem Aufwand realisierbar. Ein prozessbegleitender Einsatz der Schweißsimulation jedoch ermöglicht einen detaillierten Einblick in den gesamten Prozess.
Tagungsband: Neuere Entwicklungen in der Massivumformung, Fellbach (2013) (1,4 MB)
Autoren:
Dr.-Ing. Ralph Bernhardt, Dr.-Ing. Hendrik Schafstall
Simufact Engineering GmbH, Hamburg
Dr.-Ing. Ulrich Prahl, Dipl.-Ing. Sergey Konovalov
IEHK der RWTH Aachen, Aachen
Dr.-Ing. Markus Bambach, Dipl.-Ing. Thomas Henke
IBF der RWTH Aachen, Aachen
Artikel erschienen in: BHM Berg- und Hüttenmännische Monatshefte, May 2014, Volume 159, Issue 5, pp 208-213
Autoren:
Mario Kuss, Bruno Buchmayr
kostenpflichtig zu beziehen über Springer-Verlag Wien
Artikel erschienen in: bbr BÄNDER, BLECHE, ROHRE, Henrich Publikationen, 56. Jahrgang, Heft 5, September 2015
Autorin:
Sarah Werner
Fachartikel erschinen in: BLECH, Schlütersche Verlagsgesellschaft mbH & Co. KG, Ausgabe 6/2015, November 2015
Autoren:
Dr. Hendrik Schafstall (CTO Simufact Engineering GmbH)
Dr. Ingo Neubauer (Branch Manager Kassel Simufact Engineering GmbH)
Julian Litzkow (Engineering Services Simufact Engineering GmbH)
Artikel erschienen in: UMFROMtechnik 1/2016, Meisenbach Verlag Bamberg, März 2016
Autoren:
Dr. Gabriel Mc Bain Simufact Engineering
Thomas Terzyk Prokos GmbH
Bernhard Tönnesmann Möhling GmbH & Co. KG
Wird durch Simulation gewonnene Information genutzt in Verbindung mit Prozessüberwachungs-Systemen, lassen sich Werkzeug-Fehleinstellungen gut aufzeigen. So kann die Standzeit der Tools verlängert werden.
Mit dem Laserstrahlschmelzen, einem pulverbettbasierten additiven Fertigungsverfahren zur Herstellung metallischer Bauteile, können komplexe Komponenten hergestellt werden, welche beispielsweise in der Luft- und Raumfahrttechnik, der Medizintechnik sowie im Werkzeug- und Formenbau zum Einsatz kommen.
Fachbeitrag Schweißen und Schneiden 68 (2016) Heft 4
Autoren:
Dipl.-Wi-Ing. (FH) Thomas Töppel, Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik
Dr.-Ing. Bernhard Müller, Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik
Dipl.-Ing. Karlheinz P.J. Hoeren, Institut für Produkt Engineering der Universität Duisburg-Essen
Prof. Dr.-Ing. habil. Gerd Witt, Institut für Produkt Engineering der Universität Duisburg-Essen
Simufact zeigte neue Produktversionen seiner etablierten Produktlinien für die Umform- und Schweißsimulation / Markteinführung von Simufact Additive für additive Fertigungsverfahren
Artikel erschienen in Der Schnitt- & Stanzwerkzeugbau 1/2017
Schweißprozesse gehören nach wie vor zu den mathematisch am aufwendigsten zu beschreibenden Verfahren. Der Grund ist die lokal begrenzte Wärmeeinbringung mit ihren sehr kurzen Aufheiz- und Abkühlzeiten und den damit verbundenen Auswirkungen auf die mechanischen und metallurgischen Eigenschaften in der Fügezone. Durch die Verfügbarkeit leistungstarker Rechner bieten numerische Rechenprogramme heute die Möglichkeit, das thermomechanische Verhalten von Schweißstrukturkonstruktionen in numerischen Simulationen abzubilden.
Fachbeitrag erschienen in: ATZoffhighway 01/2017, 10. Jahrgang, Springer Fachmedien Wiesbaden GmbH
Autoren:
Dr.-Ing. Marius Gatzen, Simufact Engineering GmbH
Jochen Seifert, Edag Engineering Schweiz GmbH
Additive Fertigung besteht nicht nur aus der Generierung eines Bauteils in einem druckähnlichen Prozess. Es handelt sich um eine ganze Prozesskette unterschiedlicher Entwicklungs- und Fertigungsstufen mit jeweils unterschiedlichen Herausforderungen wie z.B. der Vermeidung von Verzug und Eigenspannungen. Die Optimierung der Prozesskette im Ganzen und ihrer individuellen Stufen kann durch die Anwendung von Fertigungssimulationen unterstützt werden. Dadurch können zeitintensive und kostspielige Iterationen mit realen Versuchen reduziert werden. Es wird ein simulativ gestütztes Optimierungskonzept auf Basis der Simufact Additive Software vorgestellt und diskutiert. Der aktuelle Stand und Beispiele aus der Praxis werden präsentiert und ein Ausblick in zukünftige Entwicklungen gegeben.
Fachbeitrag erschienen im: NAFEMS Online Magazin, Dezember 2017 - Nr. 4/2017, 44. Ausgabe
Autoren:
Dr. Patrick Mehmert, simufact engineering gmbh
Dr. Enrique Escobar, simufact engineering gmbh
Dr. Motoharu Tateishi, MSc Software Japan Ltd.
Anforderungen an Umwelt- und Klimaschutz, wachsender Energiebedarf, steigende Energiekosten sowie die Erhöhung der Sicherheit bilden den Ausgangspunkt für
Forschungstätigkeiten im maritimen Sektor. Im Rahmen des Verbundprojektes »INKOV – Entwicklung innovativer Kolben- und Ventillösungen mit Werkstoffverbunden in
Schiffsmotoren« werden metallische Werkstoffverbunde entwickelt und untersucht, durch deren Einsatz in schwerölbetriebenen Großmotoren Stickoxid-Emissionen
reduziert werden sollen.
Authors: D. Landgrebe, L.Krüger, N. Schubert, E. Jentsch, T. Lehnert
Artikel erschienen in: Werkstoffe in der Fertigung, November 2017
Hinweis in eigener Sache: Mit dem Release von Simufact Forming 15 können induktive Erwärmprozesse in der Software abgebildet werden.
Simufact gehört zu den Pionieren auf dem spannenden Gebiet der Fertigungssimulation für die metallische additive Fertigung.
Hendrik Schafstall, General Manager & CTO beim Systemanbieter, erklärt den Stand der Technik.
Interview mit Dr. Hendrik Schaftstall, Geschäftsführer & CTO, simufact engineering gmbh
Erschinen in: d1g1tal AGENDA, 1-2018
Das neue Motorhaubenscharnier LightHinge+ von Edag, voestalpine und simufact nutzt durch ein effizientes Engineering die Potenziale der additiven Fertigung. Erreicht werden so eine Gewichtsreduktion um 52 % und die Integration einer Fußgängerschutz-Funktion in verzugsoptimierter werkzeugloser Herstellung mit geringer Nacharbeit.
Autoren: 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
Erschienen in: 120 Jahre ATZ Leichtbau - Jubiläumsausgabe 2018
Der Artikel ist verfügbar über
Die Vorausberechnung von mehrstufigen Prozessketten gewinnt immer mehr an Bedeutung. Eine hinreichend genaue Vorhersage der Produkteigenschaften und Umformkräfte verlangt die Berücksichtigung von Mikrostrukturänderungen während und zwischen den einzelnen Umformprozessen. Dafür wurde eine Softwarelösung entwickelt, die in diesem Beitrag vorgestellt wird.
Autoren: Anna Back, SMS group GmbH, Dr.-Ing. Koos van Putten, SMS group GmbH, Alexander Krämer, RWTH Aachen, Ranjeet Kumar, simufact engineering gmbh
Erschienen in: massivUMFORMUNG, September 2018
Die additive Fertigung (AM) von Metallbauteilen erfreut sich in allen Industriezweigen immer größerer Beliebtheit. Einer der Hauptvorteile der AM ist die nahezu unbegrenzte Designfreiheit aufgrund der werkzeuglosen Herstellung. Sie erlaubt es, filigrane Leichtbau-Gitterstrukturen mit maximaler Steifigkeit zu erzeugen. Die AM erscheint so als perfekte Herstellungsmethode für Teile der nächsten Generation von Leichtfahrzeugen.
Autoren: Michael Wohlmuth, Michael Tran, simufact engineering gmbh
Erschienen in: MOBILES, September 2018
Simulation ermöglicht eine detaillierte Betrachtung von
Fertigungsprozessen. Die Software berücksichtigt dabei die
relevanten physikalischen Aspekte und stellt anwendungsfokussierte
Funktionen bereit.
Autoren: Dr. Hendrik Schafstall, Dr. Ingo Neubauer, simufact engineering gmbh
Erschienen in: MM-Maschienenmarkt, Oktober 2018
Additive Fertigung wirkt verlockend - jedoch ist der scheinbar einfache schichtweise Fertigungsprozess komplex - so komplex, dass der menschliche Entwickler, kaum noch alle Parameter berücksichtigen kann - spezialisierte Simulationssoftware hilft, die Komplexität zu händeln.
Autor: Dr. Hendrik Schafstall
Erschienen in: DIGITAL ENGINEERING Magazin 08-2018
Im Bereich der Kupferwerkstoffe sind neben Reinkupfersorten wie Cu-ETP1(CW003A) oder Cu-OF1 (CW007A) auch niedriglegierte Werkstoffe, z. B. auf CuMg-Basis, von immer größerer Relevanz bei der Herstellung von Feinkabeln. Die experimentelle Annäherung an die Fertigung dieser und weiterer Legierungen erfordert jedoch einen hohen Versuchsaufwand. Auf Basis eines verifizierten Modells dient die Finite-Elemente-Simulation (simufact.forming 15.0) als direkte Grundlage zur Festlegung einzelner Stichpläne. Eine systematische und umfassende Analyse des Fließverhaltens unterschiedlicher Abmessungen für verschiedene Legierungsgruppen bildet den Schwerpunkt der Studie. Hieraus sollen Erkenntnisse hinsichtlich
idealer Stichabnahme, -anzahl und Leistungsaufnahme einzelner Walzblöcke methodisch generiert werden. Diese sollen dem Fertigungsplaner als Empfehlungen für die Festlegung zukünftiger Arbeitspläne übergeben werden.
Autoren: Hertweck B.; Vetter N. R.; Seeger, C.
Erschienen in: METALL, 11/2018, 72. Jahrgang
In Teil 1 dieser Arbeit [1] wurde auf das Vorgehen zur Erstellung eines validen Simulationsmodells eingegangen. Dabei lag der Schwerpunkt auf der Beschreibung eines verketten Prozesses sowie auf des Fließverhaltens verschiedener Kupferwerkstoffe. Diese Randbedingungen bestimmen auch diesen Artikel, jedoch stehen hier die Anwendungen des Modells zu konkreten Simulationsaufgaben im Vordergrund. Es wird beispielsweise auf eine praxisnahe Fließkurvenermittlung, auf das Vorgehen bei der Reduktion der Stichfolge oder auf das Walzen von hybriden Werkstoffen eingegangen. Die so erhaltenen Ergebnisse fließen direkt in die Arbeitsplanerstellung der Produktionsplanung ein. Darüber hinaus werden diese Ergebnisse
bei Anlagenauslegung und -beschaffung verwendet, um die optimale Anzahl von Walzgerüsten abzubilden. Konkret können so Investitionsmittel für zusätzliche Zieh- und Walzstufen eingespart werden.
Autoren: Vetter N. R.; Seeger, C.; Hertweck B.
Erschienen in: METALL, 3/2019, 73. Jahrgang
Radträger für einen Rennwagen aus Aluminium fertigen? Dass ein solches Design binnen Minuten konstruiert werden kann, hat die Hexagon-Tochter Simufact auf der formnext bewiesen. Wie das funktioniert, erklärt Dr. Thomas Reiher, Director Generative Design.
Autoren: Harald Klieber
Erschienen in: AddMag, 1-2020, 3. Jahrgang, S. 28 - 33
Bitte beachten Sie die Ausführungen von Pavel Kahazan, Product Coordinator Simufact Welding zu Simufact Welding auf Seite 34 - 37.
Ausgabe Juni 2020
Bei der additiven Fertigung gilt es, noch einige Herausforderungen zu lösen. Dem Verzug beim Laserauftragsschweißen etwa hat sich jetzt eine praxisorientierte Forschergruppe gewidmet.
Autoren: Dr.-Ing. Beatrix Elsner, Dr. Frank Silze und Dr. Axel Marquardt
Erschienen in: DIGITAL ENGINEERING Magazin 03-2020
Fachartikel englisch
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.
This article is available via
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.
Artikel FASTENER TECHNOLOGY INTERNATIONAL, August 2012 (1,5 MB)
Author:
Mike Walker, Omni-Lite Industries
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.
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.
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.
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.
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.
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.
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.
Article published on occasion of the 18th 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.
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.
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.
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.
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.
Article published in the INTERNATIONAL SHEET METAL REVIEW
November 2015 (413 KB)
Interview with CEO Michael Wohlmuth at the Blechexpo 2015
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
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
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
Author:
Khazan P. (Hamburg / Germany), simufact engineering
Radel. T. (Bremen / Germany)
Woizeschke, P. (Bremen / Germany)
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
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
New Forming Software Offers Improved Operation & Covers Additional Processes
Author:
Volker Mensing, Simufact Engineering GmbH
Article published in: Wire & Cable Technology International / March 2017
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
"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
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
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
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
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
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
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
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
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
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.
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
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
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
Simufact's Michael 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
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
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
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
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
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
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
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
Simulation provides a detailed view of manufacturing processes. The software takes into account the relevant physical aspects and provides application-focused functions.
Authors: Dr. Hendrik Schafstall, Director & CEO simufact engineering, Dr. Ingo Naubauer, Director Research & Innovation, simufact engineering
Published in: ETMM Magazine - January 2019
A 3D electro-thermomechanical model is established in order to investigate liquid metal embrittlement. After calibration to a dual phase steel of the 1000 MPa tensile strength class, it is used to analyse the thermo-mechanical system of an experimental procedure to enforce liquid metal embrittlement during resistance spot welding. In this procedure, a tensile stress level is applied to zinc coated advanced high strength steel samples during welding. Thereby, liquid metal embrittlement formation is enforced, depending on the applied stress level and the selected material. The model is suitable to determine and visualise the corresponding underlying stresses and strains responsible for the occurrence of liquid metal embrittlement. Simulated local stresses and strains show good conformity with experimentally observed surface crack locations.
Authors: Julian Frei, Max Biegler, Michael Rethmeier, Christoph Böhne and Gerson Meschut
Published in: Science and Technology of Welding and Joining, February 2019
Selective laser melting (SLM) is a powder bed fusion additive manufacturing (AM) process which occurs at a high metal melting temperature. High local temperature gradients and brief cooling effects can cause residual stresses
and part deformation during 3d printing, the consequences of which can be additional surface treatment and reduced
productivity for the process. To understand how to control the formation of AM residual stresses and part form deformation, a reliable method to investigate influences between technological parameters and quality behaviours is required. There are basic physical mechanisms of the selective laser melting process that can lead to part distortion and cracking: high temperature gradients, high viscosity and surface tension of the molten powder zone, un-melted powder and oxidized particles.
Authors: A.I Khaimovich, V.V. Kokareva, V.G. Smelov, A.V. Agapovichev, A.V. Sotov Department of Aircrafts Engines’ Construction Technologies, Samara National Research University
Published in: MSC Engineering Reality Magazine, Volume IX - Summer 2019
With the continuing rapid adoption and development of additive manufacturing techniques and technologies in multiple industries led by aerospace, defense, medical and automotive, many benefits can be obtained in companies. This includes the huge potential for lightweighting, small production runs with less material waste, significant energy cost savings, and the possibility to produce functional, high performance parts that simply can’t be subtractively manufactured, cast or formed. One of the challenges is a full automation and to minimize the physical try-outs. This can only be achieved with a full digital
transformation and a fully connected workflow.
Authors: Dr. Hendrik Schafstall, Managing Director and CEO Simufact Engineering GmbH
Published in: MSC Engineering Reality Magazine, Volume IX - Summer 2019
Published in: Engineering Failure Analysis, Volume 104, October 2019, p. 586 - 577
Published in: The International Conference on Materials Science, Mechanical and Automotive Engineering and Technology, At Turkey, June 2019, available on Research Gate
Published/Presented at: NAFEMS World Congress 2019, Québec City, Canada, 17-20th June 2019
appropriate usage of simulation tools together with 3D quality data management will help provide high quality products while staying at a moderate cost level. This solution can be applied to any complex production that consists of manufacturing and assembly. A very good example is the body-in-white assembly.
Published: ams, january-march 2020
Published: Science and Technology of Welding and Joining
Article puplished in: Procedia Engineering, November 2017
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