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Structural components with Vacuum Technology in HPDC, LPDC and Gravity Die-Casting

Structural components with Vacuum Technology in HPDC, LPDC and Gravity Die-Casting

PROJECT MIUR “2mm” (Part 1 of 2) – Project Goal
Weight reduction and mechanical properties increase for automotive structural components cast in light metal alloy in Gravity Die Casting and LPDC.
Aim of the project is to produce automotive structural components for space frame with thickness reduced from 4 to 2mm by the use of innovative low pressure and gravity die casting plants and dies with vacuum, real time monitoring and closed loop logic management. Research and tuning of an optimal aluminum alloy suitable both for gravity die casting and LPDC.
Casting simulations will define alloy composition, component design, gating and evacuation system, heating die, process parameters and best fitting equipment.

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DEFORM™-2D has been used by researchers to implement wear models that relate tool wear to temperature, stresses and the sliding velocities that occur at the tool/chip and tool/workpiece interfaces. Based on the experimental wear data and the prediction of process variables by DEFORM™-2D, successful prediction of tool wear and tool life has been reported from Ohio State University.
In this work, a combination of measured and simulated values were used to predict the constants of a Usui’s (Usui, 1978) wear equation. The wear rate equation used in this study is given as follows.

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Cutting Force Prediction – Software DEFORM

Icon 21/12/2021
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Continuing advances in high performance cutting have placed ever increasing demands on cutting tools.
The design of these cutting tools influences the efficiency of material removal as well as the surface finish of the part.
New computer simulation technology reduces the amount of experimentation needed to test and optimize a new cutting tool, and thereby improves performance and time to market.

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Redesign of a Face Mill Insert – Software DEFORM

Icon 21/12/2021
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Kennametal used DEFORM™-3D simulation in conjunction with an experiment to study the effect of redesigns on a milling cutter insert.
The FIX PERFECT milling cutter with Polycrystalline Diamond (PCD) tipped inserts is a standard Kennametal product. It is used for machining aluminum alloys in the automotive and general machining market segment

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Heat Treatment simulation Grain Size Prediction – Software DEFORM

Icon 21/12/2021
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Carmel Forge, Israel, manufactures a wide range of titanium and nickel based alloy forgings for the jet engine and power generation industries. Carmel Forge uses DEFORM-2D, with the Microstructure module for their process development and optimization.
DEFORM has helped Carmel Forge to optimize their forging processes, lower production costs and significantly reduce the lead time between order placement and delivery of products.

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Heat Treat Distortion: Carbocementation deformations – Software DEFORM

Icon 21/12/2021
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Predicting and managing heat treatment distortion of complex parts is a huge challenge. DEFORM-HT is a powerful tool for simulating heat treatment processes. The system predicts heat treat distortion, residual stresses and phase volume fraction.
Heat treatment modeling helps to achieve hardness and strength requirements while minimizing heat treat distortion and residual stresses.
Kistler-IGeL GmbH, the DEFORM distributor in Germany, worked with Rob. Bosch GmbH, DaimlerChrysler AG, Institute of Material Science and Engineering of Karlsruhe and other partners on a Computer Aided Simulation of Heat Treatment project (CASH), funded by the German Federal Ministry for Education and Research. The objective was to establish a modeling methodology for the heat treatment of complex parts.

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Simulation of Induction Hardening – Software DEFORM

Icon 21/12/2021
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The DEFORM™ predicted temperature-time variations at the exit of the coil were very close to those measured via optical pyrometer in the actual process.
Applying boundary conditions to lock one end of the shaft and allow the other end to move freely facilitated the prediction of axial dilatation.
Predictions from DEFORM™-HT can provide designers and metallurgists with valuable information on the scanning induction hardening process. Shaft temperature, case depth, residual stresses and resultant distorted geometry are just some of the results available from simulation.
In addition, induction coil design can be facilitated by the DEFORM™-HT system.

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Metal heat treatment: Quench Cracking Simulation – Software DEFORM

Icon 21/12/2021
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DEFORM™-HT provides the environment for simulating quench processes and highlighting the susceptibility of cracking. Modified alloy composition, quenchant properties and process conditions may be analyzed on the computer without interrupting production schedules. In addition, fracture mechanics may be incorporated to determine the mode of failure of the cracking.

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Quench distortion of keyed shaft – Software DEFORM

Icon 21/12/2021
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Quench distortion during heat treatment is a commonly encountered problem in metal processing industries. It is considered extremely complex and is attributed to material and thermal properties of the workpiece, and quenchant properties. Phase transformations in steels further complicate the phenomenon.
It was observed that during quenching, steel shafts tended to distort more severely if they contained keyways. Non-uniform cooling due to the nonaxisymmetric geometry may have been responsible for inducing the additional distortion.

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Coining of a coin – Software DEFORM

Icon 16/12/2021
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the DEFORM Simulation Software is the only one of its kind capable of replicating the coining of a coin, without wasting material and with real results.
....

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Mechanical loads originating from filling: core deformation

Icon 14/12/2021
Icon Technical papers

Vehicles lightening is a common goal to all car manufacturers, with the aim to improve fuel economy and reduce CO2 emissions.
It is not always easy, however, to reconcile the use of light alloys and conventional forming or casting technologies with the need to manufacture structural or engine components, with thin walls, complex shapes and adequate mechanical properties.

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Optimisation of the thixoforming process by numerical modelling

Icon 14/12/2021
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Numerical modelling of mould filling and of solidification has been used for the optimisation of thixoforming production moulds. Rheological data and boundary conditions for the modelling were deduced from several sets of instrumented experiments. The simulation results could be correlated with several types of known defects. Using this simulation tool for the identification of potential defects, the geometries of gates, parts, overflows and vents have been optimised.

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The numerical simulation thixocasting with ProCAST

Icon 14/12/2021
Icon Technical papers

Numerical modeling has been used successfully as an efficient tool for converting a gravity-cast brake caliper into a thixocasting process. Procast's thixo module was used for the modeling process to achieve optimal processing parameters. The jet results show excellent correlation with the fluid dynamics and flow pattern of the model. The level and position of porosities, revealed by non-destructive X-ray and microscopic analyzes, showed a good correlation with model prediction

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Casting simulation drives component development for HPDC

Icon 14/12/2021
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High Pressure Die Casting (HPDC) enables manufacturing of large thin-walled light-weight structural components.
To remain competitive in the new global marketplace, component manufacturers in the automotive and aeronautic industries are constantly being asked to increase efficency while lowering production costs and shortening delivery times. This request from OEMs for product solutions with low energy consumption, in tandem with new requirements by the government for increase full efficency, can be satisfied using light metals such as aluminum and magnesium.

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The problem of inserts in diecastings

Icon 14/12/2021
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It is now common practice in the design of aluminum components produced by die casting to provide for the use of inserts of different material than the cast alloy.
This research was conducted with the aid of simulation software supplied to the research group. In this way it was possible to observe the progress of the filling of the impression as well as the solidification of the casting.
Article in Italian

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ZML: Versatility of simulation with ProCAST

Icon 14/12/2021
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After 5 years of concentrated and profitable use of ProCAST, ZML manages the simulation of filling and solidification as any other company activity, perfectly integrated in the cycle of products and dies development.
Moreover, thanks to this user-friendly software and to its calculation rapidity, we can evaluate in details all the small particulars which could escape through a traditional approach.
This analytic care in designing and engineering allowed ZML to broaden business horizons supplying systems for European automotive industry.

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Design and numerical validation of a die for diecasting Part 3

Icon 14/12/2021
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The design of a casting device by integrating traditional sizing and process simulation. Below is an application example of general design guidelines that can be shared for the realization of a technologically and therefore economically valid product.
Solidification analysis of the casting.
Article in Italian

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Design and numerical validation of a die for diecasting Part 2

Icon 14/12/2021
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The design of a casting device by integrating traditional sizing and process simulation. Below is an application example of general design guidelines that can be shared for the realization of a technologically and therefore economically valid product.
Filling analysis as the injection curve changes.
Article in Italian

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Design and numerical validation of a die for diecasting – Part 1

Icon 14/12/2021
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The design of a casting device by integrating traditional sizing and process simulation. Below is an application example of general design guidelines that can be shared for the realization of a technologically and therefore economically valid product.
Article in Italian

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ProCAST and CATIA integrated at GHIAL

Icon 14/12/2021
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GHIAL of Castegnato, Brescia, a well-known foundry in the field of die casting and gravity casting of aluminum alloy castings for the automotive sector, has been using a casting simulator since 2000.
The first important characteristic, ProCAST’s 2006 novelty, is the importation of the .model and .catpart native files from CAD CATIA. Lastly, GHIAL in the first place and all the foundries, die constructors and design engineers using CATIA will no longer encounter the typical problems associated with exporting geometries, from Iges, with its special tolerance, to STL which must in all cases be solid.

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FOMT: Core blowing and casting simulation

Icon 14/12/2021
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Used by Fomt for the design and production of core boxes for the distribution body of a braking system consisting of seventeen cores,
FOMT of Grugliasco, Turin, the foundry which has always been willing to invest in innovative technologies, is using the ProCAST casting simulator to its great satisfaction. The ease of use, the speed of calculation and the correspondence between the simulation and the foundry process have made it possible to achieve superior levels of quality and productivity, involving personnel – who now consider simulation to be normal activity but vital and rich in satisfaction.

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FAR Uses Simulation to Select the Right Die Casting Machine

Icon 14/12/2021
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New functionality within ESI ProCAST allows simulation to account for DCM characteristics. FAR successfully switched from one to two high-quality cavities and engineered a new die design for the right die casting machine at a minimum cost.

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ProCAST for Alupress

Icon 14/12/2021
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Alupress spa, based Bressanone (BZ), diecasting foundry since the beginning ready to invest in innovative technologies, bought the license of ProCAST, casting simulation software, after proving it for one year thanks to the flexible lease form.
In fact, this user-friendly software, its calculation quickness and the correspondence between simulation and foundry, confirmed the validity of ProCAST. It is interesting to highlight the particular technical solution chosen by Alupress for its own organising structure: floating license of ProCAST.
Thanks to this license it was possible to install the simulator on any company PC, so that each person could access to the simulation.

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Complete simulation of die container and pouring

Icon 14/12/2021
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From the analysis of more than 900 cases of diecasting simulations over a three-year period focusing attention on the filling phase, it emerged that the complete simulation of die, container and pouring should be considered to correspond to reality.
Article in Italian

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Central watch case sintering simulation – Software DEFORM

Icon 10/12/2021
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Since 2000 DEFORM has been simulating sintering processes. DEFORM allows using a tool owned by ECOTRE to create a counter deformation to correct the deformations obtained during sintering.
Article in Italian

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Pressing and Sintering Carbide Inserts – Software DEFORM

Icon 10/12/2021
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Computer simulation of the pressing and sintering process for tungsten carbide metal cutting inserts has been demonstrated. Modeling pressing and sintering using DEFORM™ can provide an opportunity for cost savings by improving the performance and reliability of the process.

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Fine Blanking simulation – Software DEFORM

Icon 10/12/2021
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The DEFORM™ System is capable of simulating blanking and piercing processes. The capabilities are included in the system, with no additional programming required. It is possible to develop different damage models and implement them via user subroutines for research applications.
While the determination of a material’s CDV is becoming more commonplace, it still requires a good understanding of the process. On the other hand, the methods used are fairly simple and straightforward.

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Virtual research saves time and real money. The Cromodora case

Icon 07/12/2021
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Working on simulation systems to measure (and modify) production processes
The more the hi-tech universe gets pushed, the more the way of thinking about it must keep up. Indeed, he must do at least two forward, overcoming it.
Article in Italian

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Simulation of hot extrusion processes – Software DEFORM

Icon 07/12/2021
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In this paper the problems of the extrusion process are discussed, the capabilities of DEFORM and the process developments are shown through several direct industrial cases of extrusion simulations.

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Recent advancements in state of the art aluminum extrusion simulations

Icon 07/12/2021
Icon Technical papers

Process modeling software based on the finite element method (FEM) is a valuable tool in analyzing metal forming processes [1,2]. Extrusion is one such process where important information can be gained by using simulation [3,4]. The material flow during extrusion can be analyzed, giving insight into the initial transient behavior in the die, weld seam formation, etc. Stresses in the die components can also be obtained using simulation, allowing die modifications to be analyzed to see if they would improve the stress state and make die cracking less likely.

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Influence of geometric dynamic recrystallization … – Software DEFORM

Icon 07/12/2021
Icon Technical papers

Finite element modeling of indirect extrusion
Multiple extrusion simulations were performed, using the DEFORM FEM code. The alloy studied was aluminum 6061, for which there are data on the thermomechanical material in DEFORM (flow stress, thermal conductivity, etc.).

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Virtual sampling with DEFORM Software dedicated to extrusion

Icon 07/12/2021
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The DEFORM extrusion simulation software shows profile and equipment problems
Excellent alignment of “Simulation Software Results” with “Reality”
The simulation allows you to identify the defects obtained during extrusion, understand their causes and then take the right corrective actions
Positive sampling at the first shot, if simulated
Certain raw material supply
Start-up times reduced to a minimum because already computer tested
Press selection: sampling and production planning
Increased die life thanks to positive samples that do not require subsequent modifications and repairs, even with possible welding
Verification of Estimate Reliability
Greater productivity

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Hydroforming Simulation – Software DEFORM

Icon 07/12/2021
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DEFORM™-3D was used in these process simulations to analyze and understand the process. The results correlated well with actual production experience.
Process simulation can be used to understand the influence of preform, plunger displacement and pressure profile on the finished product.

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Pipe forming simulation – Software DEFORM

Icon 07/12/2021
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Since this study was performed, thousands of bomb cases have been produced using the thick walled pipe.
General Dynamics has reported that the defect rate due to insufficient nose material decreased by over 20%.
Problems related to under-gauge material in the nose region and pipe bulging have been essentially eliminated.

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Chevron Crack Analysis – Software DEFORM

Icon 07/12/2021
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DEFORM has been used successfully to assist designers in eliminating existing cracks in components by providing damage levels for alternative designs. Reducing predicted damage generally reduces the probability of fracture.
The most successful damage based fracture predictions have been cases where the stress state is primarily tensile. In cases with a predominately compressive stress, damage models still require development to be effective in a wide range of processes.

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Shape Drawing simulation – Software DEFORM

Icon 07/12/2021
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Shape drawing simulations of complex three-dimensional shapes can be run in minutes for simple shapes to hours for very complex processes. A wide range of critical process information can be obtained from this type of analysis. At the quotation phase, the correct number of drawing operations requiring shaped dies can be determined.
Stress analysis can be performed on the die to ensure that low cycle fatigue fractures do not form on the inside corners. A prediction of pull loads can be used to minimize wire breaks. All of this can be accomplished without spending the time and money for shop trials.

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Integrated casting and rolling simulation: process chaining approach

Icon 07/12/2021
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1. The rolling simulation with the standard approach is performed using a homogeneous value for the input data; there is important information about continuous casting that is lost, such as residual stresses and deformations
2. The new "process concatenation approach" wants to take into consideration the production operations before rolling: continuous casting, cooling and heating furnace to better adapt to reality
3. The ProCAST software directly exports the mesh and the results in the native DEFORM format
4. This approach is useful for the continuous casting and rolling industry to increase the quality and productivity of its plants, processes and products

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Shape Rolling module – Software DEFORM

Icon 07/12/2021
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SFTC offers a range of powerful modules specific to DEFORM. Unlike the general preprocessor, modules provide customized experiences tailored to modeling particular processes. The Shape Rolling module has recently been updated and introduced in the DEFORM multi-operation environment.

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Rotary tube piercing simulation – Software DEFORM

Icon 07/12/2021
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The Eulerian formulation is not well suited to this process due to the presence of free surfaces. The Lagrangian formulation is also not well suited to this process due to the rotational motion of the workpiece, changing contact and simulation time.
An ALE method was developed for this process to allow the radial and longitudinal motions to use the Lagrangian formulation and the circumferential motion to use the Eulerian formulation.

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Virtual rolling plant – Software DEFORM

Icon 07/12/2021
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Ecotre Valente srl (BS) informs that Ferriera Valsabbia's investment in the rolling plant is with Primetals (VA). It is with great pleasure to inform you that Primetals is our very satisfied customer and user of the DEFORM rolling software. All the profiles have already been tested and sampled in the DEFORM virtual rolling plant. Primetals is able to produce twin virtual profiles and plants of the real ones.
Article in Italian

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Rolling Applications – Software DEFORM

Icon 07/12/2021
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Voestalpine Schienen GmbH carried out this shape rolling analysis using DEFORM™-3D. This tramway rail section is employed in many European cities. Ten passes are involved and the final two passes employ free-wheeling side rolls.
In the next to last pass, the side roll forms the groove in the head of the rail. This side roll was cracking prematurely and DEFORM™-3D predicted uneven pressures acting on it’s top and bottom faces. Combining the predictions from DEFORM™ with Voestalpine’s experience, the material flow was improved to give more even pressures and thus extend the life of this form roller.

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Shape Rolling simulation – Software DEFORM

Icon 07/12/2021
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Manufacturers of rolled product have used DEFORM to optimize rolling profiles and process parameters for years. Three shape rolling methods are available in DEFORM: 3D Lagrangian (3D), ALE, and 2½D. The preprocessor has been enhanced, allowing the user to prepare models with all three methods. A new specialized brick meshing capability has been added to provide an excellent starting mesh for 3D and ALE.

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Validation of hot ring rolling industrial process 3D simulation

Icon 07/12/2021
Icon Technical papers

In this work a FE model, based on Deform 3D software, was tested versus experimental results acquired from an industrial plant. The accuracy of the FE model was analyzed through a dual comparison: by geometrical and by physical aspects. A good agreement was found between experimental and numerical results for both comparisons and, as a consequence, this code could be used in order to investigate and optimize the process parameters that characterize the ring rolling process in a virtual not expensive environment. The validated model will allow the studies of more environment-friend process configurations.

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Innovation in the virtual department of ingot casting, forging and heat treatment

Icon 07/12/2021
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The ProCAST ingot casting simulation software integrated with the DEFORM forging and heat treatment software
Article in Italian

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Cogging Simulation – Software DEFORM

Icon 07/12/2021
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The DEFORM™ System contains a special pre-processor that enables the engineer to set up the complete cogging schedule in one session.
Standard industry billet, die and manipulator shapes are included and the CAD interface allows additional geometry input. Process inputs include number of heats, number of passes, rotation information, bite size and time between bites/passes.

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Process Simulation Applications in the Medical Industry – Software DEFORM

Icon 06/12/2021
Icon Technical papers

The examples have shown that computer simulation of metal forming and heat treating operations is definitely not restricted to the automotive and aerospace organizations. The medical industry can certainly benefit from reducing trial and error, not interrupting production and reduced product time to market that computer simulation offers.

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Orbital Forming Assembly – Software DEFORM

Icon 06/12/2021
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Simulation has shown that the orbital forming assembly process can benefit from a decreased feed per revolution. Decreased forming contact area requires a smaller forming load and press size. The flange provides a greater restraining force because the springback is reduced when the forming tool is removed.
However, if the feed rate becomes too low, inward material flow can occur which is undesirable. In this case, the v2 feed profile will be used because it provides the lowest feed rate at the end of the stroke without producing a defect.

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Flashless forging development – Software DEFORM

Icon 06/12/2021
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The simulation is a DEFORM™-2D axisymmetric problem with the tooling considered as rigid and only heat transfer to the tooling being simulated. The component was previously manufactured as a hot forging in the traditional manner with flash on a 1300 ton mechanical press, as shown.
By using DEFORM™-2D to assist in the design, a flashless version of the component has been developed, which also benefits from a reduced material volume in the central web – a resulting increase in material yield from 70% to 84%.

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Lap formation in a Hot Forging – Software DEFORM

Icon 06/12/2021
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DEFORM-3D was used in these process simulations to analyze and understand the process. The results correlated well with actual production experience.
Adding the bust operation eliminated this defect as a result of better volume distribution going into the blocking operation as shown. Process simulation can be used to understand the influence of volume distribution on both defect formation and product cost.
A flash region that is wide in one region and thin in another indicates a less than optimum preform design.

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Forging die wear – Software DEFORM

Icon 06/12/2021
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Existing die wear models are empirical in nature. While this is a limitation to the purist, they can be calibrated to provide useful results in a production environment. With a reasonable model, DEFORM can be used to optimize tool life for various preform designs. Die life failure analysis can contribute to very significant cost savings through increased die life without expensive production trials.

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Rolled Preforms for Forging – Software DEFORM

Icon 06/12/2021
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DEFORM simulations provided LC Manufacturing with a means to optimize part shape and avoid defects in both cross rolling and forging. For the first time ever, they were able to predict cross roll output and redesign these complex tools before physical trials. Simulation enhanced their ability to create complex preforms that could be utilized in down-stream forging sequences.
Continuous process improvement, with the aid of process simulation, resulted in a very successful product. Material use was reduced by over 30% in going from a straight cut bar to an optimized preform. LC Manufacturing has won substantial new business from their customer as a result of this success.

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Gear Blank Forging – Software DEFORM

Icon 06/12/2021
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In this example, supplied by Caterpillar, DEFORM-3D was used to evaluate various input materials in the production of a gear blank. Effective strain was used to determine if input stock with a lower initial deformation would meet the final part requirements. By accumulating strain throughout the process, the final strain distribution can be determined.

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Hot Forged Weld Yoke – Software DEFORM

Icon 06/12/2021
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The contributions of process simulation in the development of multiple cavity forgings have been well documented. This case study illustrates how DEFORM contributes to controlling cost in a tight lead time environment for a simpler process.
Tight schedules are the order of the day. Very few manufacturers have the luxury of an increased selling price to compensate for added costs associated with conservative material sizing, recutting dies or shop trials.
With profit margins as tight as schedules, it is critical to optimize the process prior to committing cash to the production trials. DEFORM-3D is a valuable tool to provide feedback to the forging designer early in the process. Even more important, when defects that would result in scrap are observed, they can be avoided completely.

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Suspension Lug Platter – Software DEFORM

Icon 06/12/2021
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Throughout the process redesign, simulation was used to test concepts prior to production trials. In the redesigned process, part location in each station was considered. Total deformation energy was calculated to estimate the number of blows required and provide a relative measurement of process efficiency. The dies were designed by Delfasco and New Die staff, while the DEFORM-3D simulations were run at SFTC within the PRO-FAST Project.

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Comparisons of Computer Fluid Dynamic Software Programs applied to Jewelry Investment Casting Process

Icon 06/12/2021
Icon Technical papers

Computer-based casting simulation as ‘virtual casting’, it facilitates us to optimize the process parameters to beneficially find out the suitable working model of the casting process. To obtain more precise and realistic solution, the profound understanding in the fundamental concept of simulation software is necessary.

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Axle Beam Forging – Software DEFORM

Icon 06/12/2021
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Process simulation can be used to determine the root cause of a defect that occurs during a multiple operation forming process. A major commercial vehicle part manufacturer discovered a problem with an axle beam forging. A lap (or fold) defect was evident on the finish forged product. History and experience guided the designers to concentrate their efforts to remove this lap on the blocker and finisher operations. In this case, modifications to the final operations did not result in a defect-free forging.

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Multiple Operation Hot Forging – Software DEFORM

Icon 06/12/2021
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The entire process was set up in one session, using material data from the DEFORM™ database, and was run a number of times with different initial billet temperatures and friction coefficients. The die movement control applied depends on the type of press machinery being simulated.

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Automotive Hot Forging – Software DEFORM

Icon 06/12/2021
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Process simulation has found many uses within UEF. Process optimization can be achieved quickly and efficiently through the use of simulation software.
Reduced product development costs and more ‘right first time’ tooling can provide significant savings.
State of the art process simulation can enable designers to explore and evaluate more challenging components that would otherwise have been possible in the past without the cost, time and risks associated with full scale, physical forging development trials.

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Aluminum Impact Extrusion – Software DEFORM

Icon 03/12/2021
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Process simulation is used to understand why a defect or problem occurs during the manufacturing process. In an ideal world, the design process would not allow these problems to ever hit the shop floor. Leading companies, such as JLO Metal Products in Chicago, Illinois have used DEFORM™ to analyze aluminum impact extrusions at the quotation stage.

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Increase of die life and part quality with DEFORM

Icon 03/12/2021
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1. The DEFORM hot forming simulation software showed the problem on the die. Excellent alignment of “Simulation Software Results” with “Reality”
2. The simulation allows to identify the defects obtained during forming, to understand their causes and then to take the right corrective actions. Positive sampling at the first shot, if simulated
3. Reliable raw material supply
4. Start-up times reduced to a minimum: bar and positioning already defined
5. Machine definition required: sampling and production planning
6. Increased die life thanks to positive samples that do not require subsequent modifications and repairs, even with possible welding
7. Estimate Reliability Verification
8. Shorter cycle time
(Article in Italian)

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Defects-in-hot-forming-Resolution-with-DEFORM-Software

Icon 03/12/2021
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1. The DEFORM hot forming simulation software showed the problem on the part. Excellent alignment of “Simulation Software Results” with “Reality”
2. The simulation made it possible to identify the defects obtained during forming, to understand their causes and then to take the right corrective actions. Positive sampling at the first shot, if simulated
3. Reliable raw material supply
4. Start-up times reduced to a minimum: bar and positioning already defined
5. Machine definition required: sampling and production planning
6. Increased die life thanks to positive samples that do not require subsequent modifications and repairs, even with possible welding
7. Estimate Reliability Verification
8. Less cycle time ....

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Incremental Sheet Metal Forming simulation – Software DEFORM

Icon 03/12/2021
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Using DEFORM™, the OSU/ERC team was able to design a progressive die sequence to make the cupped part in 10 stations. While an extra station was required in this example, the methodology was shown to be sound.
Using this methodology with experienced designers should result in fewer operations. Figure 4 shows the comparison between the emperical design and the design conducted using FEM. It can be noted that the FEM designed progression exhibits reductions that are more consistent from one station to the next. More aggressive wall thinning limits in the early stations could have been used.
This example illustrates how DEFORM™ is capable of optimizing a progressive die sequence.

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3D numerical simulation of sheet metal forming processes using solid element

Icon 03/12/2021
Icon Technical papers

This paper addresses two issues in the 3-D numerical simulation of sheet metal forming processes. One is the implementation of an effective solid element on very thin metal sheet under the bending and drawing operations. The other is the use of parallel computational scheme to reduce the simulation time. Possible volumetric and shear locking phenomena for the thin structure with solid element are avoided by adopting the assumed strain concept.

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Radiant tube forming simulation – Software DEFORM

Icon 03/12/2021
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The case study was supplied by Nicro SpA of Vailate, Italy. It was performed in partnership with the University of Brescia and ECOTRE Valente Srl of Brescia, Italy.
ECOTRE is the exclusive distributor of the DEFORM system in Italy.
SFTC and ECOTRE would like to thank Mr. Marena Gianni for sharing this DEFORM experience.

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Warm Formed Magnesium Case

Icon 03/12/2021
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Magnesium alloys can provide great weight reductions in components, which would otherwise be made from steel or polymeric materials. Those used in current structural parts tend to be die-castings, which are prone to porosity and are usually quite bulky in nature.
After 3 seconds of heating the blank in the tooling, DEFORM™ predicted the temperature distribution prior to forming ...

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The materials and the design of the die in a critical manufacturing step of an automotive shock absorber cap

Icon 03/12/2021
Icon Technical papers

The industrial drawing of automotive shock absorber endcaps caused wear and radial brittle fractures of the tool steel dies. A finite element method (FEM) simulation of the process showed that this was caused by high contact and hoop stresses on the die. Such difficulties are usually solved by expensive changes in the die material, but a change in the punch design was proposed as a simpler and cheaper solution. The new punch geometries were employed in a FEM simulation of the drawing, indicating much lower contact and hoop stresses. The implementation of the solution eliminated the wear and brittle fracture problems.

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Virtual press for die testing: product quality and equipment life – Software DEFORM

Icon 03/12/2021
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1. The DEFORM software of simulation metal sheet forming, deep drawing, progressive forming, blanking and heat treatment showed the problems on the part. Excellent alignment of “Simulation Software Results” with “Reality”
2. The simulation allows to identify the defects obtained during forming and shearing, to understand the causes and then to take the right corrective actions. Positive sampling at the first shot, if simulated
3. Reliable raw material supply
4. Start-up times reduced to a minimum: coils, strips, sheets already defined
5. Machine definition required: sampling and production planning
6. Increased die life thanks to positive samples that do not require subsequent modifications and repairs, even with any welding. Wear, elastic deformations of the die, cracks identified by DEFORM
7. Estimate Reliability Verification
8. Shorter cycle time
Article in Italian

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Optimizing Forming Load – Software DEFORM

Icon 03/12/2021
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The final design was one of a number of options simulated using DEFORMTM. The preform shape was adjusted until all critical corners were filling the die cavity at the same time during the die stroke. This optimum preform design resulted in a load that was significantly lower than the original design and the two intermediate improvements.
The final load was 515 tons, or a 22% improvement over the first preform design. It is clear that this process will be more robust and experience longer die life.

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Bolt Progression Load Optimization with DEFORM

Icon 03/12/2021
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Bolt Progression
A study was conducted on the manufacture of a flanged shoulder bolt blank on a two die – three blow header. The method of manufacture is a common one that includes trap extrusion of the initial wire, a cone upset and final forming of the head without the use of sliding dies.
In this case, the wire diameter was varried from .325” diameter thru .425” diameter, with the subsequent processes adjusted to accommodate this variation.

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Fastener Lap – Software DEFORM

Icon 03/12/2021
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During the development of a heading progression, the designer typically balances many complex parameters to accomplish a workable process. These parameters include the number of intended operations, required volumetric displacements, final part geometry, starting material size, available forming equipment and the behavior of the workpiece. Frequently, variations have existed between the designer’s concept of the progression and the actual shop trial. When unexpected metal flow occurs, this can result in a part with unfill, excessive loads, die breakage, laps, ductile fracture or other production problems. All of these problems are very costly.

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Ductile fracture during cold forming – Software DEFORM

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Fracture of the workpiece is a frequent subject of concern during large deformation cold and warm forming processes. Damage factor, as suggested by Cockcroft and Latham, can be used to predict fracture in cold forming operations. A number of Damage factors have been investigated by researchers, with the Cockcroft-Latham Damage Factor demonstrating good correlation with experimental data when the fracture occurs in a predominately tensile state of stress.

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Simulation of a Staked Fastener – Software DEFORM

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The Fabristeel Corporation of Taylor, Michigan used computer simulation to develop their self-piercing mechanically staked fasteners for sheet metal parts.
The patented drawform stud was fully developed using simulation. The development process included cold forming the stud, an installation process and a pullout test. The entire manufacturing process was developed with the aid of process simulation. Based on damage values in the sheet, the original design was modified to prevent fracture in the panel.

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Nut heat treatment simulation – Software DEFORM

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1. The simulation software must virtualize the microstructure of the material and the metallurgy of the heat treatment cycle.
2. Objective of the heat treatment: to achieve the required microstructure and mechanical performance, guaranteeing dimensions and residual stresses in the component
3. Possible problems of the hardening heat treatment: deformations and microstructures that do not comply with the regulations
4. With the DEFORM software it is possible to predict microstructure and deformations of the piece during heat treatment.

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Forged Electrical Connector – Software DEFORM

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This case study illustrates how DEFORM is highly beneficial in dimensional control and cost reduction tasks.
Tight schedules are the order of the day in the competitive forging industry. Very few manufacturers have the luxury of an increased selling price to compensate for the added costs associated with conservative material sizing, die rework or expensive shop trials.

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Some examples of Ecotre Valente’s activity: Simulation & Vacuum

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Case 1
Die casting simulation is finally complete with ProCAST. Virtualization of the diecasting machine
The occurrence of cases of mismatch between simulation and reality led Ecotre to activate a project in which over 900 diecasting simulations were analyzed over a period of 3 years. It was evaluated how correctly the casting simulation software predicted the way to fill the mold cavity and the gas porosities in the piece ....

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Demand for the “virtual factory” rises

Icon 02/12/2021
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Ecotre Valente from Brescia distributes simulation software. Growing more than 20% annually in the last 5 years
It is a matter of time. The simulation software for casting, forging, rolling, heat treatment and machining allow to expand or compress it: ingots of tons that take days, to give just one example, can be reduced and evaluated in a few minutes; conversely, steps of a few thousandths can be analyzed in hundreds of seconds. But the time factor today is also the key to the diffusion process of these virtualization programs of the production cycle. "It's only a matter of time: even in the world of steel, the tools that allow the virtual reality of production processes will be widespread."
Article in Italian

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ProCAST: introduction of press selection

Icon 02/12/2021
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ESI ProCAST 2016 is the introduction of the machine selection workflow that draws on a dedicated database for High Pressure Die Casting (HPDC) machines, including the Colosio machines.
The new functionality enables the user to define the operating point and operating zone for any machine, using the Pressure (P)- Flow Rate(Q)² graph. This information is linked to ProCAST’s solver to achieve virtual piston control in real time.

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Al Group Alusuisse: Modelling of the Thixoforming Process

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Introduction
Thixoforming process
Physical phenomena
Process Simulation
Validation
Applications / examples

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Simulation and Innovation Award with DEFORM Software: PRIMETALS TECHNOLOGIES ITALY

Icon 01/07/2021
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Elimination of scraps and defects with the DEFORM simulation software
The webinar dedicated to the novelties in Simulation of Hot and Cold Forming, Coining, Drawing, Rolling, Forging, Shape Rolling, Extrusion, Sheet Metal Forming, Shearing, Welding, Additive Manufacturing, Heat Treatments was held on Thursday 1 July 2021 and Machining with the new DEFORM 2021 Software and organized by the Brescia-based Ecotre Valente. The wide participation of the experts gave rise to an afternoon of meeting and exchange on the state of the art of metallurgical process simulation, on the criticalities encountered during production and on the prediction and resolution of defects thanks to computer simulation to obtain a high metallurgical quality.
This year Ecotre, for the "Simulation and Innovation" award, has decided to reward those companies that have distinguished themselves for their ability to innovate in the sector of presses, machines and systems. Among the 4 awarded companies: PRIMETALS TECHNOLOGIES ITALY
Lorenzo Valente, CEO of Ecotre Valente, concluded the day with these words: “We are in a moment in which the need to obtain components without defects is essential, while at the same time reducing production times and costs. The DEFORM metallurgical process simulation software is able to predict a priori the behavior of the metal during the process, evaluating defects on the product and equipment, with the aim of obtaining the maximum in terms of machine and process efficiency. ".

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Simulation and Innovation Award with DEFORM Software: AUTOMAZIONI INDUSTRIALI SRL

Icon 01/07/2021
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Elimination of scraps and defects with the DEFORM simulation software
The webinar dedicated to the novelties in Simulation of Hot and Cold Forming, Coining, Drawing, Rolling, Forging, Shape Rolling, Extrusion, Sheet Metal Forming, Shearing, Welding, Additive Manufacturing, Heat Treatments was held on Thursday 1 July 2021 and Machining with the new DEFORM 2021 Software and organized by the Brescia-based Ecotre Valente. The wide participation of the experts gave rise to an afternoon of meeting and exchange on the state of the art of metallurgical process simulation, on the criticalities encountered during production and on the prediction and resolution of defects thanks to computer simulation to obtain a high metallurgical quality.
This year Ecotre, for the "Simulation and Innovation" award, has decided to reward those companies that have distinguished themselves for their ability to innovate in the sector of presses, machines and systems. Among the 4 awarded companies: AUTOMAZIONI INDUSTRIALI SRL.
Lorenzo Valente, CEO of Ecotre Valente, concluded the day with these words: “We are in a moment in which the need to obtain components without defects is essential, while at the same time reducing production times and costs. The DEFORM metallurgical process simulation software is able to predict a priori the behavior of the metal during the process, evaluating defects on the product and equipment, with the aim of obtaining the maximum in terms of machine and process efficiency. ".

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Simulation and Innovation Award with DEFORM Software: MECOLPRESS SPA

Icon 01/07/2021
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Elimination of scraps and defects with the DEFORM simulation software
The webinar dedicated to the novelties in Simulation of Hot and Cold Forming, Coining, Drawing, Rolling, Forging, Shape Rolling, Extrusion, Sheet Metal Forming, Shearing, Welding, Additive Manufacturing, Heat Treatments was held on Thursday 1 July 2021 and Machining with the new DEFORM 2021 Software and organized by the Brescia-based Ecotre Valente. The wide participation of the experts gave rise to an afternoon of meeting and exchange on the state of the art of metallurgical process simulation, on the criticalities encountered during production and on the prediction and resolution of defects thanks to computer simulation to obtain a high metallurgical quality.
This year Ecotre, for the "Simulation and Innovation" award, has decided to reward those companies that have distinguished themselves for their ability to innovate in the sector of presses, machines and systems. Among the 4 awarded companies: MECOLPRESS SPA.
Lorenzo Valente, CEO of Ecotre Valente, concluded the day with these words: “We are in a moment in which the need to obtain components without defects is essential, while at the same time reducing production times and costs. The DEFORM metallurgical process simulation software is able to predict a priori the behavior of the metal during the process, evaluating defects on the product and equipment, with the aim of obtaining the maximum in terms of machine and process efficiency. ".

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Simulation and Innovation Award with DEFORM Software: CARLO SALVI

Icon 01/07/2021
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Elimination of scraps and defects with the DEFORM simulation software
The webinar dedicated to the novelties in Simulation of Hot and Cold Forming, Coining, Drawing, Rolling, Forging, Shape Rolling, Extrusion, Sheet Metal Forming, Shearing, Welding, Additive Manufacturing, Heat Treatments was held on Thursday 1 July 2021 and Machining with the new DEFORM 2021 Software and organized by the Brescia-based Ecotre Valente. The wide participation of the experts gave rise to an afternoon of meeting and exchange on the state of the art of metallurgical process simulation, on the criticalities encountered during production and on the prediction and resolution of defects thanks to computer simulation to obtain a high metallurgical quality.
This year Ecotre, for the "Simulation and Innovation" award, has decided to reward those companies that have distinguished themselves for their ability to innovate in the sector of presses, machines and systems. Among the 4 awarded companies: CARLO SALVI SPA.
Lorenzo Valente, CEO of Ecotre Valente, concluded the day with these words: “We are in a moment in which the need to obtain components without defects is essential, while at the same time reducing production times and costs. The DEFORM metallurgical process simulation software is able to predict a priori the behavior of the metal during the process, evaluating defects on the product and equipment, with the aim of obtaining the maximum in terms of machine and process efficiency. ".

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Simulation and Foundry Youth Award: Premiazione TECNOFORM

Icon 27/05/2021
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In Brescia, the prize dedicated to young talents in foundry simulation
The three young people that Ecotre Valente Srl, a Brescia-based metallurgical and process specialist, awarded on Thursday 27 May during the webinar dedicated to casting simulation with QuikCAST Light, QuikCAST and ProCAST software are just over twenty years old.
This is Marcello Milesi, a young 21 year old from Bergamo, of GMP Group Srl, leader in the production of alloy wheels; by Pietro Faccondini of Fonderia Morri Snc of Rimini and by Mirko Fiscato of Tecnoform Srl of Longare, Vicenza. An award that recognizes in young people skills, growth objectives in the world of work and which expresses the innovative and competitive potential of the new generations.
"In this period marked by the pandemic, young people have been able to bring innovation, skills and a positive impact into the companies throughout the metallurgical sector - said Lorenzo Valente, CEO of Ecotre Valente - The hope is that more and more young people approach the world of metallurgical process simulation, a fundamental tool in the company for reducing costs, times and scrap. "

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Simulation and Foundry Youth Award: GMP Group

Icon 27/05/2021
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In Brescia, the prize dedicated to young talents in foundry simulation
The three young people that Ecotre Valente Srl, a Brescia-based metallurgical and process specialist, awarded on Thursday 27 May during the webinar dedicated to casting simulation with QuikCAST Light, QuikCAST and ProCAST software are just over twenty years old.
This is Marcello Milesi, a young 21 year old from Bergamo, of GMP Group Srl, leader in the production of alloy wheels; by Pietro Faccondini of Fonderia Morri Snc of Rimini and by Mirko Fiscato of Tecnoform Srl of Longare, Vicenza. An award that recognizes in young people skills, growth objectives in the world of work and which expresses the innovative and competitive potential of the new generations.
"In this period marked by the pandemic, young people have been able to bring innovation, skills and a positive impact into the companies throughout the metallurgical sector - said Lorenzo Valente, CEO of Ecotre Valente - The hope is that more and more young people approach the world of metallurgical process simulation, a fundamental tool in the company for reducing costs, times and scrap. "

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Simulation and Foundry Youth Award: Fonderia Morri

Icon 27/05/2021
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In Brescia, the prize dedicated to young talents in foundry simulation
The three young people that Ecotre Valente Srl, a Brescia-based metallurgical and process specialist, awarded on Thursday 27 May during the webinar dedicated to casting simulation with QuikCAST Light, QuikCAST and ProCAST software are just over twenty years old.
This is Marcello Milesi, a young 21 year old from Bergamo, of GMP Group Srl, leader in the production of alloy wheels; by Pietro Faccondini of Fonderia Morri Snc of Rimini and by Mirko Fiscato of Tecnoform Srl of Longare, Vicenza. An award that recognizes in young people skills, growth objectives in the world of work and which expresses the innovative and competitive potential of the new generations.
"In this period marked by the pandemic, young people have been able to bring innovation, skills and a positive impact into the companies throughout the metallurgical sector - said Lorenzo Valente, CEO of Ecotre Valente - The hope is that more and more young people approach the world of metallurgical process simulation, a fundamental tool in the company for reducing costs, times and scrap. "

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The HPDC School: Let’s start the Open Seminars

Icon 29/04/2021
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In parallel to the fifth edition of the training course for technologists of diecasting, the school launches a program of technical seminars free online and open to all. Why the transfer of skills continue, and not just for students! The first online appointment to mark in your diary is May 12 at 10:00 with "Shrinkage porosity defects: casting simulation and tomography ", by Ecotre Valente, in collaboration with AQM, during which it will come treated the issue of defects in diecastings, describing the simulation software able to predict the shrinkage porosity and focusing on tomographic techniques in the diecasting sector.

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Stepped Pin – Load & Corner Fill – Software DEFORM

Icon 20/02/2021
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Process simulation was run using DEFORM to study the die fill and load requirements. The designer’s suspicions were confirmed.
The simulation allowed the designer to study the load at various forming steps and compare design alternatives for both die fill and load. The outside corner of the smallest step is the most difficult feature to fill using this process.
A redesigned progression was developed and confirmed using DEFORM to quantify the results prior to making dies.

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Simulation of heat treatment of jominy specimen to improve quality of automotive gear components

Icon 29/12/2020
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In order to validate heat treatment cycle, microstructure and mechanical properties, Jominy test has been virtualized into heat treatment simulation software. Real Jominy tests have been transferred inside simulation software for different steel grades used for automotive gear box application.
A model to forecast microstructure and mechanical properties for Jominy specimen is built and benchmarked with experimental data. Alignment between simulation results and reality allows to transfer model definition from Jominy samples to complete real components, improving quality assurance capability for real process thanks to usage of heat treatment cycle virtualization for gear box realized with different steel grades.

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The influence of heat treatment on dies

Icon 29/10/2018
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The study, carried out thanks to the commitment of the engineering team of Ecotre-Valente of Brescia, made it possible to quantify, through information technology, what happens in reality, using different extinguishing means on the same mold.
The heat treatment of Quenching and Tempering aims to confer the maximum potential of the mechanical and metallurgical characteristics developed by the chemistry of steel " Article in Italian

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Ecotre-Techne: simulation and tomography

Icon 16/06/2018
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Create virtual twins. Also virtualization did leaps and bounds, permitting to recreate with a precision that touches 100% an object directly on the monitor of a pc.
Article in Italian

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The added value of casting and vacuum simulation

Icon 29/12/2017
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We recently participated in the technical seminar "Simulation & Vacuum Metallurgy Specialist", a meeting and training day organized annually by Ecotre Valente S.r.l. of Brescia. The seminar, now in its seventh edition, took place in the evocative setting of the Mille Miglia Museum in Brescia,

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Ecotre-Colosio-ESI win the METEF innovation award

Icon 29/12/2017
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ESI’s exclusive Italian Casting Agent Ecotre Valente s.r.l, Italian Die Casting Machine manufacturer Colosio s.r.l and ESI Group were jointly awarded the METEF 2017 International Innovation Award in the “Machinery” category - For the development of an integrated simulation software / press configuration aimed at reaching the cost and quality requirements for a specified die cast product. From being empiric and approximate, the choice of a press becomes objective and precise, aligned with the characteristics of a real press. Ecotre-ESI & Colosio were located adjacently at the METEF exhibition to display this technological innovation to the die casting community.

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