Shape Rolling

Shape Rolling

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

Shape Rolling of metals: What it is

Shape Rolling is a plastic deformation process through which the material passes between rotating cylinders (rollers), smooth or shaped, that exert a crushing action thus reducing the cross-section, accompanied by elongation of the piece. The process can be carried out either hot or cold, normally with several passes between the rollers so as to achieve progressive deformation until the desired section of the laminate is reached.

Shape Rolling Simulation: How it works

Simulation of all shape rolling processes both on continuous and reversible trains and Mannesman process.

DEFORM shape rolling simulation software allows you to re-create the filling of gauges, loads, torques and motor power.
Improvements can include the capability of predicting the thermal profile, the grain size, the recrystallization and phase transformation through several shape rolling operations.
Lastly, optimization techniques can be used to improve the design of the cross-section, to minimise shape rolling stress and to predict the number of times necessary, as well as to avoid potential defects before production trials. DEFORM uses the ALE method to reduce calculation times, without sacrificing precision.

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 simulation daily to address problems with the workpiece. DEFORM can also be used in parallel by the Research & Development department for new products. DEFORM software is designed to work on desktop PC or workstation.

The Americans, manufacturers of DEFORM, came up with a complete, simple and fast software.

What customers say about DEFORM:

DEFORM shape rolling 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.
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

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

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.

Integrated casting and rolling simulation: process chaining approach

07/12/2021

DEFORM

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

Shape Rolling module – Software DEFORM

07/12/2021

DEFORM

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.

Rotary tube piercing simulation – Software DEFORM

07/12/2021

DEFORM

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.

Virtual rolling plant – Software DEFORM

07/12/2021

DEFORM

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

Rolling Applications – Software DEFORM

07/12/2021

DEFORM

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.

Shape Rolling simulation – Software DEFORM

07/12/2021

DEFORM

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.

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

Simulation and Innovation Award with DEFORM Software: PRIMETALS TECHNOLOGIES ITALY

01/07/2021

DEFORM

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. ".

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