November 2020 Volume 2

FORGING RESEARCH AND TECHNOLOGY

Figure 9: Prediction of number of forging cycles before tool crack (with permission of Minusa Tratorpeças Ltda).

Tool wear can also be predicted by QForm. In the example shown in Figure 10, you can see that the predicted die wear matches very well with the actual die wear in the shop. Tool wear can also be predicted by QForm. In the example shown in Figure 10, you can see that the predicted die wear matches very well with the actual die wear in the shop.

Figure 10: Areas with more intensive adhesion wear are shown by green, yellow, and red colors.

Figure 10: Areas with more intensive adhesion wear are shown by green, yellow, and red colors.

Users can accurately trace tracked points and flow lines forward and backward, produce graphs and numerical data from tracked points, modify the fit of inserts or shrink rings in tool simulations, and calculate user-defined functions, all in just a few seconds from the post processor. The mesh generation algorithms easily handle formation of laps and folds, intensive shearing deformation, multiple bodies like bimetallic billets or composites, as well as pre stressed die assemblies.

Users can accurately trace tra ked points and flow lines forward and backward, produce graphs a numerical data from tracked points, modify the fit of inserts or shrink rings in tool simulations, and calculate user-defined functions, all in just a few seconds from the post-processor. The mesh generation algorithms easily handle formation of laps and folds, intensive shearing deformation, multiple bodies like bimetallic billets or composites, as well as pre-stressed die assemblies. For advanced users, QForm allows easy programming and seamless display of User Defined Variables and Functions. The user has complete control over most functions via User Defined Functions (UDFs). Any kind of model, such as flow stress data, ductile fracture, or microstructure evolution, can easily be added to the programwith UDFs, which can be calculated during the simulation itself or in the post-processor, either for each instant of time or for the whole history of the process development. To implement UDFs, a method of Just-In-Time (JIT) compilation has been implemented. Anyone who has ever tried to do this on other software platforms will appreciate that no compiler is required, and these functions are performed at the same speed as the main code. QForm also allows for easy import and export into/from other programs. QForm is already in use at hundreds of companies around the world, simulating processes including: hot, warm, and cold open die and closed-die forging, ring and wheel rolling, forming of porous materials, longitudinal and transversal rolling, reducer rolling, hydroforming, bulk-sheet metal forming, cross-wedge rolling, profile extrusion, fastener manufacturing and installation, and heat

treating/microstructure a alysis. With the power and flexibility now available in new FEM software codes, combined with the availability f inexpensive high-power multi-processor computers, the optimizati n of simulation soft are for metal forming processes is poised to grow exponentially in the next decade. ■ Tom Ellinghausen Forge Technology, inc. Tom@ForgeTechnology.com Stanislav Kanevskiy QForm Group Stas@qform3d.com Sergey Stebunov QuantorForm Serg@qform3d.com

FIA MAGAZINE | NOVEMBER 2020 57