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Company
Speaker
Paper
Ceratizit Italia
Bernardo Bezzola
Optimization of carbide metal forming tools through FEM simulation
Abstract
Ceratizit Italia S.p.A. is the Italian branch of Ceratizit S.A., the biggest producer of hard metal components for wear protection applications.
Hard metal is a powder metallurgy material made of Tungsten Carbide and a binding element (f.i. Cobalt). Among many applications, hard metal is widely used for the production of tools for cold metal forming such as stamping dies, punches, knives, rolls and hammers.
Ceratizit Italia produces customized tools for cold metal forming applications in synergy with its customers. The Engineering department at Ceratizit Italia analyses application issues and customer needs in order to provide advices on the best tool design or configuration.
The FEM simulator Trasvalor ColdForm has become during the last years a fundamental tool in the design and optimization of special tools. The software is employed to study solutions from all business segments and not only in the stamping industry. Examples of these varied applications will be presented and discussed.
Best Practice on FORGE® NXT - 'Ease the Use’: demonstrations of improved functionalities with version 1.1
Abstract
The goal of this presentation is to describe how to use different major improvements of the FORGE® NxT 1.1 version.
Several developments were implemented or upgraded in the NxT 1.1 version in order to ease the use of our software:
Multi-project capability
Thickness computation
Mesh merging and export options
Thermal steady state analysis
Store manager for client/server environments
This best practice aims at providing useful recommendations and advices on these topics in order to help our customers in their everyday industrial applications.
This full presentation is not available
SKF
Stefano Galfrè
Multiple applications of Forge, from R&D to manufacturing engineering
Abstract
MCE Italy has used Forge FEM forming simulation for many years. The user friendliness and flexibility of this software have allowed to make different uses of the simulation, from the simplest study of optimized forging sequences to more advanced simulation of processes that didn't exist.
Some examples of successful experiences are shown here:
- Optimization of a forging sequence to improve the grain flow
- Investigation of the origin of a defect, through a reverse simulation of the forging sequence.
- Evaluation of achievable strain levels in a cold ring-rolling operation, in order
to design a correct range of real-scale experiments.
- Evaluation of the relationship between linear scale factor and forming loads, in order to use the results from scaled-down ring rolling tests to evaluate the
requirements for a real-scale new machine.
- Simulation of cold-rolling a totally new hollow component. The preliminary evaluation of loads on the tools allowed to design, test and patent a new
cold-rolling tooling.
- Simulation of a new process with combined impact forming and hydroforming.
Hot forging of austenitic stainless steels: Failure analysis using numerical simulations
Abstract
Due to the increasing demand of higher and higher mechanical properties and geometrical complexity of metallic parts for many industrial sectors, the interest for forging processes and their optimization remains remarkable. In this scenario, Finite Element Methods (FEM) based software actually represent the best solution to obtain fast and reliable results, but there are still significant limitations in the modelling complex material behaviours, especially when complex phase transformations take place.
The aim of the present study is the development and the implementation of an efficient and effective methodology based on the sue of FEM analyses to reduce the hot tearing during the forging of austenitic stainless steel. After a literature survey to identify the metallurgic behaviour of the material taken as case study, a FEM analysis of the forging process was carried out in order to simulate the phenomena and identify the main problems. In the second part of the work, the response surfaces method was used to evaluate the influence of the most relevant process variables.
General presentation of FORGE® upcoming major release
Abstract
This presentation aims at announcing the upcoming major release FORGE® NxT 2.0 featuring the latest enhancements related to the solver as well
as to the graphical user interface. Key-functionalities are highlighted in the field of induction heating, open die forging with real manipulators, flat rolling, mandrel forging, gas/lub trapping with deformable dies. Later, focus is given to the graphical user interface and the ease of the software introducing new features such as loading
tooling assembly, new marking grid patterns, add field by distribution and improved animation settings.
This full presentation is not available
F.O.C. Ciscato
Simone Grazian
Advantages and outlooks of implementation of numerical simulation on steel hot forging
Stefano Baù, F.O.C. Ciscato SpA
Abstract
FOC Ciscato SpA provides a wide range of forging and drop forging products. With more than a hundred years of hystory the Company is to be considered a steady point on these market. Reference markets are Transport (Railways and Marine), Oil & Gas and Energy, which demand shaft, rings, bushes, valve bodies, wheels, pipes, connecting rods, hooks, gears and planet carriers. The implementation of numerical simulation on the daily manufacturing process design has allowed interesting achievements about material usage and quality prediction. Furthermore, it allowed an easier process development for brand-new parts, where the company had limited knowledge and which would have required several real tests.
Best practice on FORGE® NXT - 'Ease the Analysis’: demonstrations inspired from frequent asked topics
Abstract
The goal of this presentation is to illustrate varied examples of FORGE® NxT 1.1 capabilities in order to have a better knowledge of the
software. Therefore the analysis of your results becomes easier and you can get more benefits from its use. The main covered topics are the following: Use of reverse marking grid to optimize preform, Automation of repetitive result analysis, Damage modeling & analysis.
This full presentation is not available
FELB
Fabio Fioletti
Development of New Shaped Ring Rolling Processes via Numerical Simulation
Abstract
Felb Srl has been established since 2006 from a demand of the market for medium weight forgings up to 10 tons, with high production flexibility due to the small batch size. This presentation introduces the experience of a SME during the introduction of Forge FEM forming simulation tool for the development of a new shaped ring rolling processes. The technical and economical benefits achieved by the new approach will be highlighted.
Strategic axis of development & Research activities
Abstract
This presentation introduces FORGE® product roadmap together with the main guidelines on Transvalor strategic axis of development. Thus, the
forthcoming evolutions on the graphical user interface are detailed and the updates related to the ongoing developments upon heat treatment and microstructure are presented as well. A special focus is also given to the recent industrial key-partnerships such as the ones upon induction heating. Finally, the mid and long term research activities will be exposed confirming the deep-rootedness of Transvalor software in R&D.