February 2024 Volume 6

EQUIPMENT & TECHNOLOGY

Digital Engineering: Pushing the Boundaries of Innovation with Simulation By Nicolas Poulain

Executive Summary As a process engineer, you face continuous pressure to optimize manufacturing processes and increase efficiency in an increasingly competitive market. To stay ahead of the competition, you need innovative tools that can help you improve the quality of forged parts and reduce energy usage and costs. One tool that can help you achieve these goals is simulation software. Recent advancements in computing software and hardware have made simulation more powerful and accessible than ever before. With modern simulation software, you can accurately simulate the entire manufacturing process, from billet heating to final operations, with greater efficiency and precision. Simulation provides you with a deeper understanding of the forging process and the quality of the forged part than ever before. Real

time simulation enables you to quickly see the impact of modifications on the part’s quality and the process’s efficiency. Even small modifications can significantly reduce costs, increase tool life, and speed up processing times for forged parts. By leveraging simulation software, you can significantly increase the speed to market, optimize processes, and stay ahead of the competition. Simulation makes all of these benefits available without the need to forge a single part, giving you greater insight and understanding without wasting material or energy. “Increased fuel and energy costs directly impact the cost of producing forged parts. These rising costs, coupled with a desire to increase energy efficiency and low carbon production, give forgers even more reason to understand how energy is used in your process and where the process can

be optimized. This is why forgers with simulation software in their toolbox have a strategic advantage over traditional forgers.” Forging: Shortcomings of the Traditional Process The traditional forging process is not known for being fast-moving or innovative. Starting with a nearly finished design, forgers will typically perform multiple trials on the part, iterating after each step. To get the part to market quicker, forgers with experience producing similar parts are required to lend their expertise, saving some iterations.

Resource Waste

Delayed Time-To-Market Reduced Product Quality

Traditional forging typically requires multiple iterations to optimize the temperature, pressure, and die design to produce a high-quality forged part. During each iteration, a significant number of resources, including raw materials, energy, and labor, are used. This process can be costly, not only in terms of resources but also in terms of time and lost rev enue due to delayed time-to market.

The traditional forging process can lead to delays in getting a product to market because it takes time to produce each batch of parts, inspect them, and make adjustments to mitigate defects. Adjustments made during each iteration may not always result in an improvement in product quality, resulting in wasted time and resources. This delay can result in missed opportunities, lost revenue, and increased costs, all of which can have a significant impact on the profitability of the manufacturing process.

Traditional forging processes can sometimes result in reduced product quality due to factors such as incorrect temperature control, tool wear, and inadequate process monitoring. Incorrect temperature control can lead to uneven deformation and cause material defects inaccurate part dimensions and surface imperfections. Additionally, inadequate process monitoring can cause variations in the final product’s mechanical properties. such as cracks, while tool wear can result in

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