November 2020 Volume 2

One time-saving feature is that the interface allows for multi-variant analysis so that any variable in a simulation can be set up with multiple variants to see how they affect the outcome of the forging without the need to manually alter the variable between each simulation. A multi-stage forging can be easily modified by copying, adding, or inserting operations anywhere in the process chain. One of the most basic functions of a simulation is verifying material fill and reducing material consumption. The example pictured in Figure 1 shows a simulation of aluminum climbing hardware run with two variations of billet size. The simulation was completed automatically in multi-variant mode. The smaller billet reduced material by 20% and still maintained a defect-free and completely-filled forging.

FORGING RESEARCH AND TECHNOLOGY

Figure 1: Optimization of billet size (with permission of DMM, Llanberis Wales, UK). Figure 1: Optimization of billet size (with permission of DMM, Llanberis Wales, UK). Underfilling is shown very easily in a simulation by a blue color on the workpiece/die contact zone. By looking at the animation with die contact activated, you can immediately see how the die fill progresses and what zones are left underfilled in the final product. Figure 1: Optimization of billet size (with permission of DMM, Llanberis Wales, UK). Underfilling is shown very easily in a simulation by a blue color on the workpiece/die contact zone. By looking at the animation with die contact activated, you can immediately see how the die fill progresses and what zones are left underfilled in the final product. die contact activated, you can immediately see how the die fill progresses and what zones are left underfilled in the final product.

Underfilling is shown very easily in a simulation by a blue color on the workpiece/die contact zone. By looking at the animation with

Figure 2: Grey area is underfilling (no contact with tool).

Figure 3 shows how several different kinds of defects are easily identified in a QForm simulation. The blue color shows die contact and the red dots show laps (surface to surface contact). Lap identification in QForm shows where the lap occurs as well as the depth and shape of the lap. If a lap begins to form, the program will not stop, it will proceed to the end of the forging chain so you can see the location and depth of the lap in the final product.

Figure 2: Grey area is underfilling (no contact with tool).

Figure 2: Grey area is underfilling (no contact with tool).

Figure 3 shows how several different kinds of defects are easily identified in a QForm simulation. The blue color shows die contact and the red dots show laps (surface to surface contact). Lap identification in QForm shows where the lap occurs as well as the depth and shape of the lap. If a lap begins to form, the program will not stop, it will proceed to the end of the forging chain so you can see the location and depth of the lap in the final product.

FIA MAGAZINE | NOVEMBER 2020 53