February 2024 Volume 6

EQUIPMENT & TECHNOLOGY

has resulted in substantial improvements in our business's output quality.

the physical bending process, saving both time and expenses. 4. Enhanced Flexibility: The example highlights the ability to consider different bend tooling designs and evaluate their feasibility. This flexibility allows for the exploration of various bending options and the selection of the most suitable approach based on the specific project requirements. Overall, Transvalor Americas has been instrumental in helping me to overcome the critical challenges I faced in my business. I am grateful for their innovative and effective simulation software solutions, which have improved my business's workflow, process, and output quality. Investing in training from Transvalor Americas will undoubtedly be a smart decision for anyone looking to enhance their simulation capabilities and improve their business's bottom line. What Anchor Harvey says: “I am thrilled to share my experience of working with Transvalor Americas and how they have helped my business to overcome critical challenges. Before I switched to Transvalor Americas, I was using a competitor's software that had long processing times and lacked precise mesh controls, which was causing significant problems for my business. Simulation is a critical tool in my industry, and the software's performance and capabilities are essential to ensure accuracy and prevent press downtime,” Rich Jogerst, Process Simulation engineer at Anchor Harvey. Simulation of the Induction Hardening Process: A Case Study While simulation is an incredibly powerful innovation, sometimes seeing the process in action is the best way to fully grasp the opportunity available to you. NTN-SNR Roulements is a global leader in bearings, transmission joints, linear modules, distribution rollers, and suspension parts. While primarily automotive, their products also touch aerospace, rail, farming, and mining segments. Known as a leader in precision engineering, NTN-SNR strives for innovation and improving its

processes and products. One of the flagship products for NTN-SNR is its bearings. They offer ball bearings for every industrial application and are known for the precision and durability of their bearings. One of the ways they achieve these characteristics is through the careful manufacturing of their bearing rings. NTN-SNR bearing rings are typically induction hardened to withstand the high stresses generated in the ball raceway contacts. Inducing hardness just in this area allows ductility to be maintained elsewhere. Geometrical distortions and residual stresses have to be minimized in the part to maintain the desired reliability and Induction hardening is a complex process involving electromagnetic, thermomechanical, and metallurgical phenomena. A simulation of the process would have to accurately model these phenomena before the process could be optimized. Any changes to the process had to be sure to maintain or increase the quality of the finished product. NTN-SNR wanted to optimize the manufacturing process but did not want to jeopardize the quality of their well-trusted bearings. These risks can often cause many companies to choose to live with inefficiencies in their product or processes instead of striving for optimization. Without improvements, NTN-SNR recognized large amounts of money and energy would be wasted over the years. Accurate simulation of the involved phenomena was required for the inductor and quenching systems used in the process for the simulation to be valid. While difficult, if the model could accurately simulate these phenomena, NTN-SNR would be able to understand two major aspects of their process and parts: • The setpoints applied to the generator like current, power, and frequency • The impact of changes in temperature, residual stresses, distortions, and microstructures during the process performance characteristics. The Problem for NTN-SNR

Figure 5: Bending operation progression

The Benefits 1. Design Validation: By utilizing a bending simulation and CAD overlay, the example allows for the validation of the bend tooling design before its actual implementation. This helps to identify any potential issues or mismatches between the intended bent shape and the part design early on, saving time and resources. 2. Precision and Accuracy: The use of bending simulation and CAD overlay enables precise and accurate visualization of the bent shape. It ensures that the desired specifications, including the bend radius and angle, can be achieved with the chosen bend tooling. 3. Time and Cost Efficiency: By employing a simulation-based approach, potential design flaws or mismatches can be identified and addressed in the virtual environment. This reduces the need for costly trial and error iterations during

FIA MAGAZINE | FEBRUARY 2024 16