Incremental Sheet Metal Forming

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

Incremental Sheet Metal Forming: What it is

Incremental Sheet Metal Forming is a production method that involves different types of machining through a series of workstations. These workstations can include forming, bending, cutting and other forming techniques, and are carried out in a specific order along the sheet-metal path. All the stations along the path can be processed with a single movement of the machine, whenever the mould performs the work stroke, it completes all the stations simultaneously, but on separate stations. The process usually starts with the sheet from the coil which moves forward “progressively”, undergoing all the processes in sequence until the finished product is made. The final workstation is usually cutting of the piece.

Incremental Sheet Metal Forming Simulation: How it works

Incremental Sheet Metal Forming simulation for all alloys.

DEFORM shows incompleteness, folds, strips, sink marks, cracks, machine loads, wear and die damage.

DEFORM Incremental Sheet Metal Forming simulation software is American and has been optimised to be reliable, quick and easy.

DEFORM software has an attractive and easy to use graphical interface. The software guides the user step-by-step in importing geometries, selecting materials and setting process parameters. These tasks require little effort by personnel. The following phase is calculation of the simulation, displaying how the piece is being formed while the software is computing. The standard 6, 8 and 12 core workstations are computers that reduce waiting times by a few hours for a complete simulation. Results on hand, DEFORM automatically shows the defects and problems that the mould mounted on a given press, operated in a certain way, would have produced in the department.

Ecotre Valente offers solutions to metallurgic and quality problems together with its partner PentaP Srl of Bergamo: www.pentap.it

• PentaP is the Otto Bihler Maschinenfabrik GmbH & Co. KG partner in Italy for the provision of CAD bNX software training, support and formation solutions.

• PentaP simulates operations with DEFORM for all Otto Bihler Maschinenfabrik GmbH & Co. KG press or equipment mould designs already guaranteeing conformity of the results on a design level.

In the automotive, electronic and medical industries, the level of excellence currently demanded of these products requires features, both of the product and equipment, driven ever more to guarantee compliant results.

These components are made with presses of up to 1,500 strokes/min and with Incremental Sheet Metal Forming dies made with extremely efficient materials and technologies.

The DEFORM simulation software of the production process, already at the initial stage of an industrialization process, makes it possible to assess the feasibility and quality of the results.

Assessing the deformation conditions, with equal process parameters, makes it possible to determine which is the most suitable solution to best achieve each individual operation, also highlighting the accumulation of stress on the component.

The operations in sequence are then further optimised to limit temperature and wear of all the involved tools.

The thirty-year experience with this type of product and the intuition provided every day in the delicate design stage, are supported by the bending process simulation with DEFORM software, which, through numerical values and clear and easy results, makes it possible to immediately verify the effectiveness of the new solutions proposed.

What customers say about DEFORM:

DEFORM Incremental Sheet Metal Forming 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
STARTING TIMES REDUCED TO A MINIMUM The press setting was already tested in simulation. The real sampling will dispose of the machine setup card already defined.
CERTAIN RAW MATERIAL PROCUREMENTThe DEFORM deforming simulation makes it possible to assess different extruded item diameters and therefore to immediately identify the diameter for each code
REQUIRED PRESS 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

PentaP: complete support for sheet metal forming with DEFORM

29/12/2021

DEFORM

PentaP supports die makers through the service of virtualization of the forming process, or the FEM simulation through the use of software DEFORM, distributed exclusively in Italy by Ecotre Valente of Brescia. “The results obtained are a lot interesting and allow our customers to evaluate immediately what are the intrinsic problems of a forming, with a very high reliability, the results they are close to reality ”, underlines the owner.

Ecotre Valente offers solutions to metallurgical and quality problems with the partner PentaP Srl of Bergamo: www.pentap.it

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

Incremental Sheet Metal Forming simulation – Software DEFORM

03/12/2021

DEFORM

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.

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

03/12/2021

DEFORM

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

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