Furnaces metallurgical simulation - Ecotre Valente

Furnaces

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

Furnaces Simulation: What and how it works

A heating furnace must therefore guarantee, in addition to excellent production, ideal heating quality and ever less energy consumption and emissions for lower environmental impact. At the same time it needs to maintain competitive capital and operational costs.

Simulation of heating furnace, single or multiple load furnace. Shorter loading times, less stresses, very slow transformations, steady-state furnaces, less transients.

In order to achieve all of these goals, for comprehensive optimisation of the furnace and reduction of energy consumption, the 3D computational thermal-fluid-dynamic simulation of the complete furnace comes into play.

Furnace Simulation

Through geometrical changes and changes to the combustion system, simulation of the heating furnaces makes it possible to analyse thermofluidodynamic details of the gases inside the furnace and to compute the comprehensive energy balance and heating curve of the load. The simulation also allows you to analyse in detail the fluidodynamic features of the gases, the effectiveness of the combustion blend, the thermal distribution on the walls and the temperature and thermal flow on the load.

The ProCAST and DEFORM heating furnaces simulation software programs reproduce the heating furnaces/complete treatment while considering movement of the load in the furnace.

The software output includes graphs, images, tables, animations and STL shapes, and the material database includes a wide range of steel, aluminum, alloys, titanium, copper and other materials.

What customers say about DEFORM:

DEFORM furnaces 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 forming, to understand their causes and therefore to undertake the right corrective actions

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

Furnaces

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

Furnaces

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

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

29/12/2021

Furnaces

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.

Modeling the heat treatment of ausferritic ductile iron

28/12/2021

Furnaces

Ausferritic ductile iron (ADI) combines the freedom of the molding style of cast iron with the strengths of steel. ADI forms by heat treatment of nodular cast iron. To take full advantage of the technical potential of this material, extensive controls of the casting and the heat treatment processes are required. The authors describe an integrated approach of experimental studies and modelling for optimum process design. The simulation tools developed permit exact predictions of the microstructure due to the heat treatment. If certain suitable technical parameters are observed, an ausferritic microstructure without pearlite, martensite and bainite can be obtained. The parts produced had very good reproducible mechanical properties distinctly better than the applicable limits

Heat Treatment simulation Grain Size Prediction – Software DEFORM

21/12/2021

Furnaces

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.

Heat Treat Distortion: Carbocementation deformations – Software DEFORM

21/12/2021

Furnaces

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.

Simulation of Induction Hardening – Software DEFORM

21/12/2021

Furnaces

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.

Metal heat treatment: Quench Cracking Simulation – Software DEFORM

21/12/2021

Furnaces

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.

Quench distortion of keyed shaft – Software DEFORM

21/12/2021

Furnaces

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.

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

07/12/2021

Furnaces

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

Nut heat treatment simulation – Software DEFORM

03/12/2021

Furnaces

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.

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

03/12/2021

Furnaces

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

Furnaces

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

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

29/12/2020

Furnaces

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.

The influence of heat treatment on dies

29/10/2018

Furnaces

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

Ecotre-Techne: simulation and tomography

16/06/2018

Furnaces

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