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Metal Forming Simulation

Metal Forming Simulation Artificial Intelligence Analysis FEA|CFD & AI Integration

Using advanced Metal Forming Simulation methodology and FEA tools such as Ansys, Ls-dyna and Abaqus for any bulk material forming deformation, combining with experience and development have made Simulation Dynamics the most reliable consultant partner for large material deformation simulation.

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Metal Forming Simulation, Integrated FEA|CFD with Artificial Intelligence

Cold Forming

Regarding cold forming, it is true that it is restricted to easily formable materials, or materials that can be easily transferred into a formable microstructural state. This is because cold forming involves applying pressure to a material at room temperature, which can cause it to deform plastically. If the material is too hard or brittle, it may not be able to withstand the required deformation without cracking or breaking. Therefore, materials such as aluminum, copper, and low-carbon steels are commonly used in cold forming processes.

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Cold Forming, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
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Hot Forging

Hot forging is a manufacturing process that involves shaping metals above their recrystallization temperature. During hot forging, the material is heated to a temperature where it becomes malleable and ductile, allowing it to be shaped into complex 3D geometries.

Hot forging is used for materials that are difficult to form at room temperature, such as high-strength alloys, which can be formed only with limitations when cold. The higher temperatures used in hot forging make these materials more malleable, allowing them to be formed into complex shapes without cracking or breaking.

Hot forging is a highly specialized manufacturing process that requires careful control of temperature, pressure, and forming time to ensure high-quality parts with the desired mechanical properties. Finite element simulation with Ansys, LS-Dyna and Simulia Abaqus can be used to model and optimize the hot forging process, allowing engineers to predict and control the behavior of the material during forming.

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Hot Forging, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
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Open Die Forging

Open die forging is a forging process used for large and critical products that cannot be formed using basic forging processes due to their high deformation load or massive dimensions. In open die forging, the metal is shaped by compressive forces applied by a pair of flat dies that do not completely enclose the workpiece, allowing the material to flow and form to the desired shape.

The technological processes of open die forging are often used to produce individual, low-volume parts for die blocks, rings for further rolling, blanks of crankshafts for marine engines, and other large parts requiring the characteristics and durability of a forging. Open die forging can be used with a variety of materials, including steel, aluminum, titanium, and other metals and alloys.

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Open Die Forging, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
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Roll Forming & Ring Rolling

Rolling processes are used in all areas of forming technology, both in hot forging and cold forming, and of course in sheet metal forming. In a rolling process, material is deformed by applying compressive forces between two or more rollers, which reduces the thickness or changes the shape of the material. During the process, the material undergoes significant deformation and strain, which can lead to defects such as cracks, voids, and surface imperfections.

Finite element simulation be used to model the rolling process and predict the behavior of the material during forming, including the formation of defects. By adjusting the process parameters such as temperature, pressure, and forming time, engineers can optimize the process to produce high-quality parts with the desired mechanical properties.

Simulation also be used to analyze the effect of different rolling techniques, roller geometries, and lubrication on the final product. This can help engineers to design and develop new rolling processes that are more efficient, cost-effective, and produce higher quality parts.

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Roll Forming & Ring Rolling, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
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Sheet Metal Forming

Advanced finite element analysis (FEA) tools such as Ansys, LS-Dyna and Abaqus can be used for sheet metal forming design and simulation to evaluate the feasibility of the project and predict the behavior of the material during the forming process. FEA can provide valuable insights into the material behavior, which can help engineers optimize the process parameters and reduce the risk of defects such as cracking, tearing, and wrinkling.

During the sheet metal forming process, the material is subjected to significant deformation and strain, which can lead to defects such as cracking or tearing. FEA can be used to simulate the entire process and predict the likelihood of these defects occurring. The simulation results can also provide information about the wall thickness distribution, edge curvature, and hardness distribution in forming steps, which are important factors to consider when designing sheet metal parts.

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Sheet Metal Forming, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
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