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Full Representation of Shop Floor Forging Practice
Advantage by Increased Insight
TheThe Virtual Forging Shop Virtual Forging Shop
MSC.SuperForgeMSC.SuperForge
How is Full Representation Achieved?
• Comprehensive Material Data
• Realistic Press Characteristics
• Accounting for Friction
• Accounting for Temperature Effects
• Accounting for Elasticity
• Automatic/Manual Positioning of Work Piece
• Handling of Multi-Stage Processes
• Powerful CAD Interface
• Available in Database Form
• Select Material by “mouse-click”
• User-extendable Database
Comprehensive Material Data
• Material Data depends on
– work hardening
• temperature
– strain rate
Realistic Press Characteristics
• Most Press Types Available
• User-extendable Database
• Most Press Types Available
Friction
• Friction Influences:– load and energy requirements– metal flow– pressure distribution– die wear
• Friction Models– Coulomb friction– plastic shear friction– combination
• User-extendable Database
Temperature Effects• Needed to account for:
– proper metal flow – die chilling during forming– thermal stresses during cooling
• Heat Transfer between Work Piece and Dies
• Heat Transfer to Ambient
• Heat Conduction within both Work Piece and Dies
• Heat Generation due to Plastic Deformation
Elasticity Effects
• Needed to account for:– deviation from desired shape (tolerances)– thermal stresses– proper die loads (die overclosure)
• Elastic-plastic material model
Positioning of Work Piece
• Influences Metal Flow
• Automatic or Manual Positioning– sliding is accounted for !!
Accurate Workpiece Positioning
Multi-Stage Process Modeling
• Automatic Transfer of Material Properties between Stages– stress, strain, temperature
• Transport of Work Piece between:– furnace and dies– different dies
• Intermediate Heat Treatment• Handling by “mouse-click”
Powerful CAD Interface• CAD Transfer via STL (Standard Triangulation Language)
– standard format used in rapid prototyping techniques– commonly available in all CAD packages
• No ‘Finite Element’ Experience Required
• No Meshing
STL
• Why ? – enables precise filling of intricate die regions if metal
flows into such regions– no user intervention required
• Able to capture small intricate die details by using:
Resolution Enhancement Technology (RET)
Advantages of MSC.SuperForge
Industrial Examples
Forging of an Automotive Cap
pressure on tool
MSC.SuperForge
Selected Reference Accounts