SOLUTIONFOR THE AUTOMOTIVE INDUSTRY

M A T E R I A L F O R M I N G S I M U L A T I O N

FORGE®

Crankshaft

forging load central looseness

metal flow quenchingfolds/laps underfilling

Connecting rod

heat treatment reducer rollingflash trimming yield improvement

material cost reduction automatic optmization

power train transmission chassis

rotary swaging net shape die life

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We, at Transvalor, fully understand the challenges of supplying forged automotive components. Over the past 25 years, FORGE® has been the perfect solution in predicting the usual shop floor issues and to help designers, metallurgists and R&D engineers overcome their technical issues and optimize their processes.

FORGE®

is the solution to:

• Design First Time Right forging sequences and dies

• Reduce design cycle

• Minimize real scale try-outs

• Increase yield

• Extend die life

• Optimize and consolidate quotations.

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to validate and optimize the entire forging sequence from pre-forming stages up to heat treatment analysis.

FORGE® is a comprehensive simulation software

FORGE® is the solution

to increase productivity

and reduce costs

Accurate prediction of the geometry for all stages of a steering knuckle Bharat Forge Ltd., India.

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FORGE® makes it fast and easy to validate the complete forging sequence, for any type of component, chassis, transmission or powertrain parts and predicts:

FORGE® allows very accurate predictions of material flow including underfillings

such as shown in this picture (underfillings in red).

Folds/laps are identified in red in this simulation of a

steering knuckle.

Prediction of the grain flow of a one cylinder crankshaft and comparison with

the real part: the localization of the un-deformed area by FORGE® is in

close correlation with the experiment.

Underfillings and excess material

Folds/laps

Grain flow to localize un-deformed areas or internal folds

Underfilling

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Improve your forging sequence & deliver high quality components with the unique features of FORGE®

Central looseness tracking.

Shear surface tracking of the initial billet up to the final geometry.

The position of the central looseness of a crankshaft has

been tracked during the complete forging process and is represented

in the final shape.

Localization of the shear surface tracking of the initial billet of a connecting rod. Shear surface is represented at different stages: end of reducer rolling, end of edger, end of finisher.

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Component distortion during trimming for high accuracy simulation.

Cold formed netshape components by rotary swaging process.

Trimming of a commercial vehicle component is represented here. With FORGE®, the distortion generated on the part by the trimming process is taken into account.

This application illustrates the coldforming of a hollowshaft by rotary swaging.This CPU demanding simulationis achieved thanks to the use of the bi-meshmethod. This technique allows significant CPUtime reduction by using two different meshes forthermal and mechanical solving.

4 cores 6 cores 12 cores 24 cores

CPU time

Speed-up chart for a 3 stage connecting rod forging simulation.

Powerful and flexibleHighest speed-up with FORGE® HPC (High Performance Computing)

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FORGE® can accurately predict stress, abrasive wear and temperature distribution in the dies as well as forging load and equipment deflection.

Increase die life and optimize equipment with the FORGE® fully integrated die analysis feature

Crack initiation in the die cavity of a yoke connection.

HirschVogel Umformtechnik GmbH

Abrasive wear on a punch using Archard law.

Hatebur Umformmaschinen AG

Forging load prediction in the finisher stage.

Fatigue crack initiation in the die cavity.

Actual & Simulated Die Wear.

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Extensive forming equipment kinematicsMechanical press, hydraulic press, screw press, hammer, knuckle joint press, direct drive press, orbital forging press, forging machine, ring rolling mills, flow forming mills.

Unique competitive

advantages of the FORGE® die analysis feature

FORGE® offers unique features to calculate:

Die temperature at a steady state

Thermal and mechanical analysis into the dies (including die deformation) at any time of the process with a fully coupled or uncoupled computation

Pre-stressed dies

Spring loaded dies

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Pioneer and market leader in automatic optimization

CASE 2 • This control arm is made of standard steel with an initial billet weight of 5.6Kg. The forging sequence is made of three stages: bender, blocker and finisher. Thanks to the FORGE®

optimization features linked with a CAD system, the initial billet weight has been reduced to 5.1Kg, saving 10% of material per part.

CASE 1 • The objective of this automatic optimization is to minimize the cut weight in order to save material. The forging sequence of this steering sector shaft is made of 5 stages, 3 preforms, blocker and finisher. The input material is a rectangular billet (RCS). Transitions between each stage are managed automatically by FORGE®. The parameters to be optimized are the billet length and width.

Automatic parameter settings in the CAD system.

AUTOMATIC OPTIMIZATION

H

RCS

The optimum billet dimensions were automatically found by FORGE® resulting in a 9% saving in material.

Flash pattern before (in red) and after optimization (in blue).

Flash pattern before (in red) and after optimization (in blue).

CASE STUDIES10 www.transvalor.com

FORGE® provides the highest flexibility with unlimited access to the Graphical User Interface for 64-bit pre and post processing. License fees are related to the number of computer cores regardless of the number of users. Extra flexibility benefits are:

Job scheduling

2D and 3D automatic transitions between stages

Dynamic token allocation across multiple and remote sites (Floating license)

Solver support for up to 64 cores in parallel (one simulation can be executed on 64 cores concurrently)

Token borrowing

Unmatched Flexibility

> User #1

> User #2 > User #3 > User #4

> User #5

FORGE solver

Pioneer and market leader in automatic optimization

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FORGE® WORLD LEADING NUMERICAL SIMULATION SOFTWARE

Besides its headquarter located in France, Transvalor has a worldwide presence with a comprehensive network of distributors, offices and subsidiaries for both marketing and support activities.

Transvalor has developed an extensive suite of high performance simulation software that addresses a wide range and variety of forming processes, for metallic solid and liquid materials as well as for polymers :

FORGE® for extensive hot, warm and cold metal forming,

COLDFORM® for cold metal forming

THERCAST® for ingot casting and continuous casting,

Rem3D® for plastic injection & composites molding.

Transvalor products provide the manufacturing and engineering intelligence to a wide range of industries Automotive, Aerospace, Energy, Medical, Oil and Gas and many others.

Transvalor success comes from a comprehensive expertise of the forming processes and an unyielding capability to innovate. The value of Transvalor Material Forming Simulation Solutions can also be measured in business terms as they dramatically reduce production

costs, shorten time to market and accelerate the delivery of innovative products.

As such we help our customers

• Gain a deeper and broader understanding of their material behavior as well as their processes,

• Optimize and shorten their design process by almost eliminating the slow and painful “trials and errors” in the shop-floor,

• Increase manufacturing quality.

Transvalor is born of Research and has maintained a strong association with the Center for Material Forming (CEMEF), a research center of prestigious MINES ParisTech, whose main activities are centered on material forming and numerical computation.

This partnership provides a constant flow of advanced scientific developments that translate into innovative new functionalities to Transvalor’s products for the benefit of our customers.

Parc de Haute Technologie694, avenue du Dr. Maurice Donat 06255 Mougins Cedex - FrancePhone: +33 (0)4 92 92 42 00 Fax: +33 (0)4 92 92 42 01Email: marketing@transvalor.com

TRANSVALOR S.A.

TRANSVALOR HAS BEEN CERTIFIED ISO 9001: 2008 BY THE BUREAU VERITAS QUALITY INTERNATIONAL (BVQI) FOR THE DEVELOPMENT, INDUSTRIALISATION AND LICENSING OF COMPUTED-AIDED ENGINEERING SOFTWARE AND RELATED SERVICES. THIS CERTIFICATION SHOWS THE WILL OF TRANSVALOR TO PROGRESS AND TO ANSWER BETTER ITS CUSTOMERS’ EXPECTATIONS.

Transvalor, leading Software Editor of Material Forming Numerical Simulation

Pantone Reflex Blue

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Pantone Cool Gray 7

Pantone Reflex Blue

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