Simufact Forming Cold Forming serves the simulation of bulk forming processes below the recrystallization temperature of the material. The module helps you to prevent common manufacturing errors such as:

• Lap formation
• Markings created by shearing edges
• Insufficient die filling
• Cracks
• Excessive press and die loads

Simufact Forming Cold Forming

considers all relevant boundary conditions, including stress rings and spring supported dies. The realistic prediction of the forming forces, while taking into account spring back effects and the elastic-plastic material behavior, is necessary for a high precision simulation of cold forming processes.

Utilize the advantages of Simufact Forming for your cold forming processes:

• Reduced testing effort during design and prototyping
• Shorter development times
• Optimized stage planning according to press capabilities (Press force distribution of individual stages)
• Higher process understanding of complex die designs (spring supported dies, flashless precision forging)
• Optimized die life through investigation of die loads
• Correct die material selection
• Optimized design of stress rings
• Higher process stability and quality

Nowadays the simulation of hot die forging is an integral part of a modern CAE environment.

Simufact Forming combines easy and intuitive usability with a reliable prediction of forging processes. The simulation results are useful for advanced product and process development, for the continuous optimization of series processes, and feasibility studies during program bidding.

Simufact customers report sustainable savings and competitive advantages such as:

• Reduced development costs through fewer development loops
• Reduced trial costs (Production Part Approval Process ‘PPAP’ or Prototyping, pilot series)
• Increase of new business due to shorter time-to-market performance (get faster ‘Start of Production’ (SOP))
• Declining fixed costs through higher machine utilization
• Lower quality control costs via higher process stability and quality
• Lower manufacturing costs through improved material yield (reduction of forging flash and excess material)
• Reduced manufacturing costs due to fewer process stages
• Less scrap and lower rework costs
• Lower tool cost through increased tool life
• Reduced energy costs through better efficiencies of individual process steps
• Prediction of component properties

Modeling of entire process chains

Simufact Forming enables modelling of entire process chains in hot forging beginning with the supplying of raw material (billets, slugs, blanks), an initial heat treatment/heating, upsetting, pre- and finish forming, trimming, shearing, punching, calibrating, cooling and final heat treatment.