Under the umbrella of Hexagon Manufacturing Intelligence (HMI), AICON 3D systems (AICON), Forming Technologies Inc. (FTI) and Simufact Engineering will present at their joint booth at the EuroBlech fair in Hanover, how design, engineering, manufacturing, and measurement technology can be combined into a digital process chain for sheet metal forming.
Following the principle of digital thread, Hexagon solutions bring together production phases of design and engineering (CAD, CAE), manufacturing (CAM) and measurement technology (metrology) to an agile, data-driven ecosystem. Intelligent solutions can increase productivity through quality improvements in order to give customers a significant competitive advantage.
Case Study Seat Cross-member
The three partners prepared a showcase of the digital thread to illustrate their performance in the sheet metal forming process chain. By means of a seat cross-member, a sheet metal part, the companies illustrate the exemplary performance and interaction of their software and hardware solutions at the EuroBlech booth.
On the basis of CAD-component data, FTI’s software solutions initially support Design for Manufacturability (DFM) to test and then modify the product design. At an early manufacturing development stage, a first forming feasibility study could be carried out based on the component geometry. This could then determine conclusive modifications to the part geometry. Additionally, the initial manufacturing method plan and accompanying determination of the material and dies costs could follow. This information supports the organization in cost estimation, and contributes to an optimized process design for sheet metal parts.
Based on this, Simufact solutions focus on the manufacturing processes. Their software assists in the design and optimization of (multi-stage) forming processes, mechanical and joining processes and even additive manufacturing processes. Virtual testing of sheet metal processes reduces the number of trial runs by using realistic predictions of the geometrical accuracy, cracking behavior, risk of cracking, and formability The simulation results show the product’s characteristics such as wall thickness distribution, edge curvature, and the hardness distribution due to cold working.
Finally, AICON measurements solutions survey the manufactured part using optical 3D measurement and validate the accuracy in the manufacturing. A comparison of the measurement results in reference to the geometry provides information about any tolerance violations that may exist.
“See What You Measure“ – AICON enters into a new dimension of fringe projection. Using the SWYM technology, it is now possible for the first time to visualize the results of a measurement directly on the object. The adaptive full color projection technique enables projection not only of the color patterns which are necessary for the scanning process onto the object, but also of the generated measurement results. This, for instance, allows for the deviations from the CAD to be visualized in color immediately following the measurement on the surface of the scanned object.
Considerations can be made on this basis, for instance how to adjust process parameters in order to achieve the goal of an accurate part.
Meet FTI, Simufact and AICON at the EuroBlech in hall 11, booth G93. We have allotted an amount of time to take concerns and questions, therefore we kindly ask you to make an appointment.
Simufact´s new software version for simulating metal forming processes comes with stability, accuracy, and speed enhancements
New functions for smarter pre-processing and Mechanical Joining simulation
Simufact Engineering has released its new product Simufact.forming 13. The new version provides improvements in post processing, evaluation and the depiction of the simulation results, result precision, software stability, and speed. Simufact.forming 13 offers a range of functional enhancements.
User-defined Result Values: With user-friendly mathematical formulas, users can now generate their own result values based on those of the simulation. In many cases, this new function renders the programming of subroutines completely unnecessary. Users can define their own color schemes for the depiction of result quantities and therefore can evaluate simulation results according to their own criteria. This function simplifies the post processing process when examining the variables in the design process. Routine designs can be automatically evaluated, which substantially cuts down the time taken to find the best design for the manufacturing process.
Tracking of Post Particles: Post particle tracking helps you to find the causes of typical mistakes in a massive forming process. Post particles are user-defined measuring points for the parameters. The user can define them after the actual simulation, during post processing, and during all process steps whilst running the simulation both forward and backward. If a simulation indicates an imperfection, such as a fold formation, under-filling or overfilling of the die, the user can define the measuring points during post processing. For example, if under-filling is shown, users can put post particles on the indicated location and trace it back to the point where too little material was used in the initial geometry. The process can therefore be optimized to meet the requirements.
Innovation in the Application Module Mechanical Joining: Users who apply Simufact.forming for the simulation of mechanical joining processes, can look forward to new developments in the application module Mechanical Joining. In the new version, the geometrical properties of hollow self-pierce riveting processes are automatically determined and visualized. This helps users to quickly evaluate the highly realistic results of the simulation with just the push of a button. Furthermore, predefined templates now support the design of self-pierce riveting processes.
More Functional Enhancements
Status display for remote synchronizing: The status bar was expanded to display the status of remote synchronizing -the transfer of the simulation results to the local client. This function is useful for client-server installations where calculations are done on network resources rather than on the client.
Shared-memory parallelization: The more powerful shared-memory parallelization (SMP) replaces multiple-threading parallelization. SMP reduces computation times by up to 50 percent when simulating with the FE-solver by implementing an additional parallelization to the assembly of the stiffness matrix. Computation times with the FV-solver are shortened by 10 to 25 percent.
Automatic definition of symmetry levels: The automatic definition of symmetry planes saves the user the time and effort it would take to manually define the planes and the time and effort needed to adjust the press force and its maximum force.
Export results using the I-DEAS Universal format: Simulation results can now be exported for further use in the I-DEAS Universal format, e.g. for a subsequent structure simulation.
Simufact.forming is an established and wide spread software solution for the design and optimization of metal forming processes. Car manufacturers and their suppliers, rail vehicle construction companies, aerospace companies, and mechanical engineers are the primary users of Simufact.forming.
Simufact® is a registered trademark of Simufact Engineering GmbH. All other trademarks belong to their respective owners.