Open Die Forging simulation of metals

Open Die Forging

DEFORM Benefits

Quality improvement
Optimization and saving in the design
Improvement of production
Enhanced precision
Flexibility of use
Reduction of calculation times
Reduction of production rejects
Saves money

Metal Forging: What it is

Forging is a massive deformation process carried out hot to give metal semi-finished products their final shape and size. Forging can be carried out in a closed mould, to obtain parts including complex shape, or in an open mould, in this case more properly called forging: meshes or hydraulic presses deform the ingot heated in specific high-temperature furnaces giving them the wanted shape.

Forging Simulation: How it works

Forging simulation, complete with blooming, impression making, stretching, tapping, blanking, heating and holing. Optimization of ram geometry, closing of core defects and superficial quality.

DEFORM forging simulation software is dedicated to this special process where we Italians are a world reference. In recent years, forges have upgraded the heat treatment department and thanks to DEFORM this delicate and strategical technological area can be simulated. Heat Treatment makes it possible to maximise the performance of the materials and of the components being operated.

DEFORM is a tool dedicated to production and is therefore simple to use. The technical operator, the quality department and the technical department will use forging simulation daily to address problems with the forge. DEFORM can also be used in parallel by the Research & Development department for new products. The Americans, manufacturers of DEFORM, came up with a complete, simple and fast software.

What customers say about DEFORM:

DEFORM forging simulation software is American and has been optimised to be reliable, quick and easy.

EXCELLENT AGREEMENT OF “SOFTWARE RESULTS” WITH “REALITY” DEFORM is the most widely used cold forming simulation software in the world
SAMPLING IMMEDIATELY POSITIVEThe simulation makes it possible to identify defects obtained during forging, to understand their causes and therefore to undertake the right corrective actions
STARTING TIMES REDUCED TO A MINIMUM The machine setting was already tested in simulation. The real sampling will dispose of the machine setup card already defined.
CERTAIN RAW MATERIAL PROCUREMENTThe DEFORM forging simulation makes it possible to assess different extruded item diameters and therefore to immediately identify the diameter for each code
REQUIRED MACHINE DEFINITION DEFORM indicates the required tonnage for each workstation and therefore indicates which machine is necessary for the process. Planning of samplings and production
LONGER MOULD DURATION Tool wear known and reduced thanks to modified mould mechanics. Mould damage phenomena eliminated because expected and therefore taken care of in simulation

For the purchase, hire or a DEMO of the software or if you want to take advantage of a simulation service specially-made by our technical department, write or call us at +39 030 3365383

References

DEFORM: A software to combat expensive energy

22/02/2022

DEFORM

Ecotre Valente from Brescia proposes DEFORM to optimize costs through process simulations
Not only reductions in shiftwork and production in the lower cost ranges, energy savings can also come from a simple one software.
A popular saying goes that "necessity sharpens the wits", meaning that when you are in critical conditions it is a process of nature find new solutions to problems, and in this case to costs.
Precisely in the face of the expensive energy Ecotre Valente, it has decided to offer its customers a new weapon represented by the software DEFORM for the simulation of energy consumption in furnaces...
Article in Talian

Eliminate scrap and defects with simulation

29/12/2021

DEFORM

The webinar dedicated to the novelties in the simulation of hot and cold forming, coining, drawing, shearing, rolling, forging, drawing, extrusion, welding with the new software DEFORM 2021 and organized by the Brescia-based company will be held on Thursday 1 July 2021.
Article in Italian

Grain flow in Forgings – Software DEFORM

29/12/2021

DEFORM

Our main focus was on closed die forging for the previous items in this series. In this, however, we will consider preforms and large components, which are often produced by open molding.

Simulation software for ingot casting, forging, shape rolling and heat treatment

29/12/2021

DEFORM

The metallurgical sector is experiencing a time of change with the demand for increasingly complex components, light, performing and high performance. The new software QuikCAST Light, QuikCAST, ProCAST 2021 and DEFORM 12.1 support steel mills, forgers, calibrators, foundries, die makers, metallurgists and designers, as they virtualize their own process and create a virtual department in which to try in advance the equipment, the production cycle and execute a preview of the quality control on the product. up to to any heat treatment and mechanical processing final providing information related to quality, properties mechanical and structural features of the product.

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

07/12/2021

DEFORM

The ProCAST ingot casting simulation software integrated with the DEFORM forging and heat treatment software
Article in Italian

Cogging Simulation – Software DEFORM

07/12/2021

DEFORM

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.

Process Simulation Applications in the Medical Industry – Software DEFORM

06/12/2021

DEFORM

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.

Flashless forging development – Software DEFORM

06/12/2021

DEFORM

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%.

Forging die wear – Software DEFORM

06/12/2021

DEFORM

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.

Gear Blank Forging – Software DEFORM

06/12/2021

DEFORM

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.

Suspension Lug Platter – Software DEFORM

06/12/2021

DEFORM

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.

Axle Beam Forging – Software DEFORM

06/12/2021

DEFORM

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.

Forged Electrical Connector – Software DEFORM

03/12/2021

DEFORM

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.

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

03/12/2021

DEFORM

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 ....

Demand for the “virtual factory” rises

02/12/2021

DEFORM

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

Ecotre-Techne: simulation and tomography

16/06/2018

DEFORM

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