Benefits with DEFORM
- High-quality welded products
- Elimination of rejects and reduction of defects
- Elimination of sampling
- Improved mechanical properties of the part
- Greater part strength
- Reduced welding times
- Reduced welding costs
DEFORM simulates the welding process known as "Rotary Friction Welding"
Rotary Friction Welding (RFW) is a well-established technology capable of joining metallic materials through the combined action of friction, pressure and deformation, without melting the material. During the process, one part is rotated against a second, stationary component under an axial load. The mechanical energy is converted into heat by friction, locally heating the materials to a plastic state. At the end, rotation stops and a forge force is applied to consolidate the joint.
With DEFORM it is possible to accurately simulate every stage of this process, reducing testing time and costs. The software makes it possible to input the actual geometries and the materials involved, and to define critical parameters such as:
- Heating pressure and time
- Friction pressure and time
- Spindle speed (rpm)
- Forge (upset) pressure and time
The simulation returns essential information such as the evolution of temperature, residual stresses, flash morphology, axial shortening and plastic deformation. The results obtained with DEFORM’s FEM model have been compared in the literature with experimental tests on spheroidal (ductile) cast iron, showing high accuracy in predicting thermal peaks (over 1200 °C), in the stress distribution and in the estimation of the final shortening of the welded parts.
Thanks to advanced thermo-mechanical modeling, it is possible to optimize the process “recipe” by acting on friction conditions, part geometry and thermal cycles, in order to achieve reliable welds even in materials that are difficult to join, such as ductile cast irons. With DEFORM, every stage is predicted in advance, leaving only equipment commissioning to production.
What customers say about DEFORM:
The DEFORM rotary friction welding simulation software is American and has been optimized to be accurate, fast and simple.
- EXCELLENT ALIGNMENT BETWEEN “SOFTWARE RESULTS” AND “REALITY” DEFORM is the most widely used rotary friction welding simulation software in the world.
- SUCCESSFUL SAMPLING RIGHT AWAY Simulation makes it possible to identify the defects produced during rotary friction welding, understand their causes and therefore take the right corrective actions.
To purchase, rent or request a DEMO of the software, or if you would like a custom simulation service from our technical department, write to us or call us at +39 030 3365383
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