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Simufact Forming 15.0 Whats New en

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0% found this document useful (0 votes)
219 views117 pages

Simufact Forming 15.0 Whats New en

Uploaded by

Tiago Chalinski
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 117

What’s new in Simufact Forming 15.

0
Simufact product design goals

 Ease of use
▪ Manufacturing-oriented GUI
▪ For tool and process designers
▪ Integration into customer workflows

 High fidelity
▪ Best-in-class result accuracy
▪ High speed & stability
▪ Covering all important process steps

Copyright © simufact engineering gmbh


 Agile
▪ Continuous integration of customer requirements

Simufact Confidential Copyright © simufact engineering gmbh 26.03.2018 2


Process chain integration - materials to systems
Materials Fabrication Parts Assembly Systems

Digimat MSC Apex MSC Nastran

Digimat-VA Marc Actran - Acoustics

Digimat-AM MSC Apex

MaterialCenter SC/Tetra - CFD

Adams

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Virtual Test Drive

Simufact Confidential
MSC Software Confidential
Copyright © simufact engineering gmbh 26.03.2018 3
Integrating the best technologies

• Combining proven technologies from


– MSC
– Hexagon
– 3rd parties

Copyright © simufact engineering gmbh


• Developments shared between all Simufact products
for full inter-operability

Simufact Confidential Copyright © simufact engineering gmbh 26.03.2018 4


Highlights of Simufact Forming 15.0

 New process types (process chain)


▪ Induction heating
▪ Case hardening (carburizing)
 General usability
 Improved process setup
 Improved result evaluation
 Improved result quality, meshing and calculation time
 Data exchange
 Documentation

Copyright © simufact engineering gmbh


 MSC licensing, setup and configuration
▪ New MSC licensing (based on FLEXlm)
▪ Improved setup

Simufact Confidential Copyright © simufact engineering gmbh 26.03.2018 5


Highlights of Simufact Forming 15.0

 Improved result evaluation


▪ Postprocessing functionalities
➢ Result query
➢ Path plot
➢ New legend functions
➢ New result value „surface deviation“
▪ Result transformation
▪ Enhanced result management

Copyright © simufact engineering gmbh


Copyright © simufact engineering gmbh 26.03.2018 6
New features in Forming 15.0

New process types (process chain)


▪ Induction heating
▪ Case hardening (carburizing)

Copyright © simufact engineering gmbh


Copyright © simufact engineering gmbh 26.03.2018
New process type – inductive heating

 Inductive heating that considers the real electromagnetic field


▪ Fields of application: pre-heating, surface heating for heat treatment  case
hardening
▪ Advantages:
➢ Fast, homogeneous, localized heating
➢ High productivity
➢ High reproducability  high quality

▪ How does induction work?

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➢ AC current in an inductor (coil) creates an electromagnetic field, which induces an
eddy current in a workpiece. This eddy current creates resistance heating.

Bilder: http://www.ews-konnerth.at/de/himmelwerk sowie


http://radyne.com/what-is-induction/basics-of-induction/

Copyright © simufact engineering gmbh 26.03.2018 8


New process type – inductive heating

14.0 15.0

 Idealized model  Harmonic electromagnetic simulation of

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 Definition of near-contact the magnetic flux lines and eddy currents
 Simulates the (conductive)  Transient thermomechanical simulation
heat transfer of the workpiece temperature field

Copyright © simufact engineering gmbh 26.03.2018 9


New process type – inductive heating

Benefits
 Which inductor geometry yields a

Inductor (coil)
homogeneous temperature field?
 to reach a homogeneous
hardness distribution
 Best coupling distance between
workpiece and inductor?
 Process parameters?
 Temperature field?
 …

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Temperature distribution

Schematic representation

Copyright © simufact engineering gmbh 26.03.2018 10


New process type – inductive heating

 Add real induction heating simulation


▪ Coupled electromagnetic, thermal, metallurgical, mechanical computation
of the inductive heating is possible
▪ Multi-phase materials are supported for magneto-
dynamic pass
▪ restricted to 2D (but 3D can be unlocked)
▪ New process type „inductive heating“ added
➢Process type available in all application modules
➢New components were created
(inductor , near field , far field )

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▪ No additional license is required, available in
Simufact Forming Hub

Copyright © simufact engineering gmbh 26.03.2018 11


New process type – inductive heating

 Definitionof electromagnetic
properties for the induction field

➢Current (constant / table)


➢Frequency
➢ Total cross-sectional area
➢ Number of turns
➢ Cross-sectional shape and dimension
➢ Current flow direction

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Copyright © simufact engineering gmbh 26.03.2018 12
New process type – inductive heating

 Definition of coil path was added for 3D inductor geometry


▪ Several options of path definition via points, via automatic calculation
or via CSV import

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Copyright © simufact engineering gmbh 26.03.2018 13
New process type – inductive heating

 Local adaptive refinement is supported for induction heating processes


▪ Type: magnetic potential gradient
▪ 2D and 3D simulations

 User-friendly definition of contact table for induction heating and induction


welding processes

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▪ Electromagnetic components (inductor, far field, near field) can only be in contact with
other electromagnetic components
▪ Contact type of the electromagnetic components is always "glued“
▪ Nonsensical contact settings are not allowed

Copyright © simufact engineering gmbh 26.03.2018 14


New process type – inductive heating

 Added magnetic result values to the result group


“Electromagnetic”

Magnetic potential

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Copyright © simufact engineering gmbh 26.03.2018 15
New process type – inductive heating
 The material properties are defined in the material database as electro-
magnetic properties.

 All properties can be defined as a function of the temperature


▪ Mechanical properties
▪ Thermal properties

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▪ Electromagnetic properties (electrical conductivity / resistance, relative
permittivity, relative permeability)
 JMatPro materials can also provide electromagnetic properties

Copyright © simufact engineering gmbh 26.03.2018 16


New process type – inductive heating
 Material properties can optionally be defined as phase-dependent
 Properties of the air and the coils must be defined as linear-elastic
 Any workpiece movements (displacements or forces) can be defined using
(tabular) presses.

 Limitations:
▪ DDM parallelization is not supported yet,
but SMP
▪ Coils cannot be moved
➢ Define workpiece movements instead

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Copyright © simufact engineering gmbh 26.03.2018 17
New process type – inductive heating
 Definition of magnetic flux contollers (concentrators) are possible
▪ Reduction of external field
▪ Higher power in the part at the same coil current
Magnetic potential

Without concentrator

With concentrator
Temperature [°C]

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Higher power in the part at the
same coil current

Copyright © simufact engineering gmbh 26.03.2018 18


New process type – inductive heating
 Documentation
▪ New D&E example with detailed tutorial description
▪ New infosheets

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Copyright © simufact engineering gmbh 26.03.2018 19
New process type – inductive heating

Click the play


button to play the
video!

Copyright © simufact engineering gmbh


Info: If the animation does not start, the videos are saved in the following installation path (\ simufact \ forming \ 15.0 \ doc \
sfForming \ Tutorial \ Videos) or check our Simufact YouTube channel.

Copyright © simufact engineering gmbh 26.03.2018 20


New process type – inductive heating/-hardening

 Induction heating and -hardening processes can be simulated

Workpiece

Water
(cools the workpiece until
martensit tranformation)

Hardness
Inductor

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(heats the workpiece to the
austenitizing temperature )

Surface core

Copyright © simufact engineering gmbh 26.03.2018 21


Linear temperature-dependent austenitization model

 Linear temperature-dependent austenitization model is supported


▪ Austenitization is calculated linearly between the A1 and A3 temperatures during
a heating process with phase transformation.
▪ Cooling and heating can be set up physically correctly in one process (e.g.
volume change).
▪ Important for "small" or partially austenitized or not completely warmed-up
components.

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Copyright © simufact engineering gmbh 26.03.2018 22
Linear temperature-dependent austenitization model

 Linear temperature-dependent austenitization model is supported


▪ Basic dilalometer test - result comparison V14 and V15
▪ Detailed simulation of the property change during heating (e.g. volume change)

Volume [%] 14.0

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15.0
with linear austenitization model

Copyright © simufact engineering gmbh 26.03.2018 23


New process type – carburizing

 Carburizing (case hardening)


▪ Carbon diffusion (carburizing) + hardening
▪ Carbon diffusion influences the near-surface of a component (property changes)
▪ New process type “case hardening” in heat treatment module

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Copyright © simufact engineering gmbh 26.03.2018 24
New process type – carburizing

▪ Powder carburization, salt bath carburization as well as gas and low-pressure


carburization can be set up ( different carburization velocity)
▪ Protective atmosphere (e.g. paste) possible to prevent carburization locally

Carburization boundary condition


Carbon potential
Carburization velocity

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Diffusion coefficient
Carbon concentration Protective atmosphere

Copyright © simufact engineering gmbh 26.03.2018 25


New process type – carburizing
 Additional options:
▪ Possibility to switch sub-aspects of the coupled analysis on or off depending on
the substage
▪ Result output frequency can be defined depending on the substage
▪ Local adaptive mesh refinement possible via the diffusion gradient
▪ Linear temperature-dependent austenitization model is also supported in case
hardening
▪ Use of cyclic symmetry in a DDM calculation possible ( computation time)

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Copyright © simufact engineering gmbh 26.03.2018 26
New process type – carburizing

 Extensive Documentation
▪ New D&E example with detailed tutorial description
▪ New infosheets

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Copyright © simufact engineering gmbh 26.03.2018 27
New process type – carburizing

Click the play


button to play the
video!

Copyright © simufact engineering gmbh


Info: If the animation does not start, the videos are saved in the following installation path (\ simufact \ forming \ 15.0 \ doc \
sfForming \ Tutorial \ Videos) or check our Simufact YouTube channel.

Copyright © simufact engineering gmbh 26.03.2018 28


New features in Forming 15.0

General usability
▪ Improved positioning during model setup
▪ Improved measurement capability
▪ Improved clipping functionality

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▪ Improved model check

Copyright © simufact engineering gmbh 26.03.2018


General usability
New infosheet

 Improved interactive positioning capabilities for


model setup
▪ Unified for all Simufact products

Translation mode

Rotation mode

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Positioner mode
Bounding box mode

Copyright © simufact engineering gmbh 26.03.2018 30


General usability

 Improved interactive positioning capabilities for model setup


▪ Definition of rotation point for positioning possible

Translation mode

Rotation mode

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Positioner mode
Bounding box mode

Copyright © simufact engineering gmbh 26.03.2018 31


General usability

 Improved interactive positioning capabilities for model setup


 Unified for all Simufact products
Click the play
button to play the
video!

Translation mode

Rotation mode

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Positioner mode
Bounding box mode

Copyright © simufact engineering gmbh 26.03.2018 32


General usability
 Improved interactive positioning capabilities for model setup

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Copyright © simufact engineering gmbh 26.03.2018 33
General usability

 Added the possibility to represent several measurements at once in model


and result views

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New infosheet

Copyright © simufact engineering gmbh 26.03.2018 34


General usability

 If model components are positioned that have already been meshed, the
mesh is not deleted anymore
 Comments from the process definition dialog are shown as a process tooltip
(max. 5 lines)

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Copyright © simufact engineering gmbh 26.03.2018 35
General usability

 Improved model check before submitting a simulation


▪ Model check allows working on the process while opened
▪ Extended advice how to handle errors and warnings in model check
▪ Links to dialogue where something needs to be changed partially

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Copyright © simufact engineering gmbh 26.03.2018 36
General usability

 Improved contact settings for deformable-deformable contact


▪ Avoiding penetrations between deformable bodies

 Added and reworked shortcuts to make them more consistent with other
products
▪ Open DAT File from GUI  STRG+Shift+D (previously STRG+X)

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Copyright © simufact engineering gmbh 26.03.2018 37
General usability

 Added a message box when the GUI is about to be closed. The


message box can be deactivated if needed.
 Rotation of view is now animated
 Added brass to the materials selectable in the function "heat up

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Copyright © simufact engineering gmbh 26.03.2018 38
New features in Forming 15.0

Improved process setup


▪ Hot forging improvements (FV)
➢ Fold detection
➢ Ramp up

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➢ New backstroke substage
➢ Improved surface meshing

Copyright © simufact engineering gmbh 26.03.2018


Improved process setup – hot forging

 Improved display of result “possible folds”


▪ Result is represented with two colors (red: folds, gray: no folds)
▪ Detected folds are marked with fold markers
▪ Result variable is always written
▪ Finite volume is supported only

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Copyright © simufact engineering gmbh 26.03.2018 40
Improved process setup – hot forging

Click the play


button to play the
video!

Copyright © simufact engineering gmbh


Info: If the animation does not start, the videos are saved in the following installation path (\ simufact \ forming \ 15.0 \ doc \
sfForming \ Tutorial \ Videos) or check our Simufact YouTube channel.

Copyright © simufact engineering gmbh 26.03.2018 41


Improved process setup – hot forging

 High order solver is also used for heating and cooling processes
▪ Scaling factors can be edited in the GUI

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Copyright © simufact engineering gmbh 26.03.2018 42
Improved process setup – hot forging

 Time ramp function (up/down) can also be defined depending on stroke:


▪ V14: energy-dependent for energy-driven presses
▪ V14: time-dependent for stroke-driven presses
▪ V15: energy-, time-, stroke-dependent (recommended)
Time scaling factor

Time sclaing factor

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Energy Stroke

Copyright © simufact engineering gmbh 26.03.2018 43


Improved process setup – hot forging

 New substage backward stroke for FV simulations


▪ Workpiece is released after forming substage (elastic energy is released)
▪ Avoids lifting of workpiece during subsequent heating / cooling steps
▪ Reduces volume loss

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 Dieload processes in FV project with automatically shortened tool names can
be set up

Copyright © simufact engineering gmbh 26.03.2018 44


New features in Forming 15.0

Improved process setup


▪ Improved user-defined complex
kinematics

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Copyright © simufact engineering gmbh 26.03.2018
Improved process setup – complex kinematics

 New kinematics version 2 available with


new features for a more flexible GUI setup.
 Main improvements for version 2:
▪ Multiple-page navigation (structured GUI for
high numbers of input values)
▪ Dialog-wide CSV import and export (comfort Content /
Image
file
function for extensive GUIs) Multiple
page
Input

▪ Use tables as input data (e.g. for rolling navigation Editable brief description and linkable infosheet

curves) Dialog wide CSV import and export

▪ Use formulas for input fields (automatic


calculations in the GUI)

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▪ New, flexible and easy-to-read .kin file
format
 Drawback: pass table not compatible
anymore

Copyright © simufact engineering gmbh 26.03.2018 46


Improved process setup – complex kinematics

 Translation files: Use this new file type


to create GUIs dependent on
language settings. They can also be
used to keep variable names in the
kinematics files short while displaying
more descriptive names in the GUI.
 Simple foolproofing system: Define Translation file
min and max attribute values for every
input field. If the entered value
exceeds this range, it will be
highlighted and triggers a warning in

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the model check.
 New singleStep attribute: Define the
step size for spin boxes.
Copyright © simufact engineering gmbh 26.03.2018 47
Improved process setup – complex kinematics

 With Simufact Forming 15 the data format of the


XML file that describes the contents and
appearance of the user-defined kinematics dialog
had to be changed. The new file extension is
.udk (user-defined kinematics file).
 This applies to both versions!
 It is still an XML file but with a different file
extension. Please change the file extensions of
already existing .xml files to .udk.
 Additionally all files used by the kinematics file
such as images or infosheets need to be placed

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in a corresponding sub-folder. The sub-folder
name should be identical with the base name of
the .udk file <baseName>.udk.

Copyright © simufact engineering gmbh 26.03.2018 48


New features in Forming 15.0

Result evaluation
▪ New THS value „mechanical work“
▪ Result query
▪ Path plot
▪ New legend functions
▪ New result value „surface deviation“
▪ Result transformation

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▪ Improved clipping functionality
▪ Enhanced result management

Copyright © simufact engineering gmbh 26.03.2018


Result evaluation

 New THS value “mechanical work”


▪ For all dies attached to a stroke-dependent
press with movement along z-axis
▪ For all dies with a die spring/generic spring with
degree of freedom in +- z-direction
 Restrictions
▪ Not available for stationary dies
▪ Not available for special tool kinematics, e.g.
ring rolling, open die forging.

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Copyright © simufact engineering gmbh 26.03.2018 50
Result evaluation

 New THS value „mechanical work“


▪ Mechanical work for press includes
energy to compress die spring Energy induced to
spring + workpiece

Energy induced

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to workpiece

Copyright © simufact engineering gmbh 26.03.2018 51


Result evaluation

 THS values exclusively for energy presses


(hammer, counter-blow hammer, screw press)
▪ Gross available energy
▪ Gross delivered energy
▪ Net delivered energy
▪ Efficiency

 For counter-blow hammer the sum of upper


and lower dies is displayed

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Copyright © simufact engineering gmbh 26.03.2018 52
Result evaluation

 Display forces for springs and contact forces individually for each tool as well
as summarized for the press
 Make user-defined result values and THS values accessible to the optimizer
 Implement user-defined THS values
 Add function to stage control to transfer a result step based on max or min user
THS value
 Added copy to clipboard via shortcut in THS plots
 Removed obsolete controls in THS plot window

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Copyright © simufact engineering gmbh 26.03.2018 53
Result evaluation

 New query dialog with extended functionalities


▪ Option to query results on nodes or between
nodes

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▪ Result values and position of selected points
can easily be compared out of the query dialog

Copyright © simufact engineering gmbh 26.03.2018 54


Result evaluation

 New query dialog with extended functionalities


▪ Several results can be shown in the dialog
▪ Different processes can be compared

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Copyright © simufact engineering gmbh 26.03.2018 55
Result evaluation

 New query dialog with extended functionalities


▪ Additional information contains scaled coordinates and original coordinates as
well as result values and node numbers

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▪ All data can be copied (via mouse or ctrl-C) and pasted directly into MS Excel

Copyright © simufact engineering gmbh 26.03.2018 56


Result evaluation

 New query dialog with extended functionalities


▪ Selected results can easily be exported to CSV

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Copyright © simufact engineering gmbh 26.03.2018 57
Result evaluation

Click the play


button to play the
video!

Copyright © simufact engineering gmbh


Info: If the animation does not start, the videos are saved in the following installation path (\ simufact \ forming \ 15.0 \ doc \
sfForming \ Tutorial \ Videos) or check our Simufact YouTube channel.

Copyright © simufact engineering gmbh 26.03.2018 58


Result evaluation
 Improved path plot functionalities
▪ It is now possible to select particles, define sampling points between them and
get a path plot of some result value over those points

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Copyright © simufact engineering gmbh 26.03.2018 59
Result evaluation

 More options in result management: possibility to exclude results with


prestate data, last load case results, last simulation results

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Copyright © simufact engineering gmbh 26.03.2018 60
Result evaluation

 New result transformation added


▪ Interpretation of results in local coordinate
systems
▪ Detailed comparison with reference geometry
(measuring geometry) or initial geometry

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Copyright © simufact engineering gmbh 26.03.2018 61
Result evaluation

 New result transformation added


▪ Added the possibility to use reference geometries (for instance surfaces from a
measurement) or initial shape to be used for visualization
▪ Several methods to define coordinate systems
➢ 3-2-1 definition
➢ 3-point definition
➢ Measuring table
➢ Cylindrical coordinate system

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Copyright © simufact engineering gmbh 26.03.2018 62
Result evaluation

 New result transformation added


▪ Active transformation is visualized in the GUI
▪ Transformation can easily be removed
▪ Transformation can be exported as an XML file and loaded again, it is
immediately applied then
▪ Total displacements are also recalculated

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Copyright © simufact engineering gmbh 26.03.2018 63
Result evaluation

 Added color legend scaling factor to legend properties

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Copyright © simufact engineering gmbh 26.03.2018 64
Result evaluation

 New color legend indicators for min and max values of results

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 Minimum and maximum legend ranges can be edited directly
in the result view

Copyright © simufact engineering gmbh 26.03.2018 65


Result evaluation

 Added new result value “surface deviation”


▪ Representation of vertical distortion (distortion in normal direction)
▪ Surface ripple visible

Surface normal direction

blue: displacement vector


red: shown displacement

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(surface deviation)

Copyright © simufact engineering gmbh 26.03.2018 66


Result evaluation

 Significant improvements in clipping function

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 For materials with defined hardness data, initial data are written to avoid
large areas with undefined hardness due to missing cooling rate

Copyright © simufact engineering gmbh 26.03.2018 67


New features in Forming 15.0

Result evaluation
▪ Improvements for
resistance spot welding
Improvements for

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mechanical joining

Copyright © simufact engineering gmbh 26.03.2018


Result evaluation

 Added new automatic measurement for resistance spot welding simulations


▪ Display measurement in THS plot
▪ Measured values are nugget height (NH), nugget width (NW), width of heat-
affected zone (HAZ), joint width (JW), joint height (JH) and contact width
between electrode and sheet (CW)
▪ Two or three sheets are possible
▪ 2D axisymmetrical processes only

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Copyright © simufact engineering gmbh 26.03.2018 69
Result evaluation

 Added expulsion model to resistance welding processes with automatic


measuring
▪ Expulsion is detected when nugget width of the used sheets is greater than both
electrode-sheet contact widths. Right now the expulsion detection is global for all
sheets

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 Added a new D&E example in Simufact Demos
 Added user subroutine interface for equation for electrical contact coefficient

Copyright © simufact engineering gmbh 26.03.2018 70


Result evaluation

 Rigid dies with heat conduction as load-controlled bodies are now supported

Rigid die with heat conduction


Generic spring +
die insert

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Copyright © simufact engineering gmbh 26.03.2018 71
Result evaluation

 Added database for most wanted coatings for resistance spot welding
▪ New predefined table with type: temperature – electrical resistivity
▪ Table for coating resistivity can be selected in contact table

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Predefined table

Copyright © simufact engineering gmbh 26.03.2018 72


Result evaluation

 Added new measurement values for self-piercing riveting simulations


▪ Automatic measuring for vertical interlock, gap distance and foot diameter
▪ Measuring results are displayed in THS plot (history plot)
▪ Definition as variable in user-defined result value possible

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Copyright © simufact engineering gmbh 26.03.2018 73
Result evaluation

 Definition of the dial gauge radius for measuring the rivet head end position is
possible in the GUI:

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Copyright © simufact engineering gmbh 26.03.2018 74
New features in Forming 15.0

Result quality
▪ New damage models
▪ Crack propagation (2D) based on plastic
damage models

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▪ Support combined hardening material
model

Copyright © simufact engineering gmbh 26.03.2018


Result quality

 Added new damage models


▪ Gurson model and modified Gurson model (Tvergaard and Needleman)
▪ Bonora model (similar to Lemaitre damage model)

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Copyright © simufact engineering gmbh 26.03.2018 76
Result quality

 Implement strain rate and temperature dependency for Johnson-Cook


damage model

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Copyright © simufact engineering gmbh 26.03.2018 77
Result quality

 New 2D damage-based mesh separation


▪ Benefits are local refinement, smooth surfaces along crack, no volume loss

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Copyright © simufact engineering gmbh 26.03.2018 78
Result quality

 New 2D damage-based mesh separation


▪ Blanking process
▪ Self-piercing riveting process

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Copyright © simufact engineering gmbh 26.03.2018 79
Result quality

 Added the definition of hardening model


 Added the possibility to define the hardening model via temperature-
dependent tables

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▪ GMT material data are not supported
▪ Only FE is supported

Copyright © simufact engineering gmbh 26.03.2018 80


Result quality

 New grain size calculation MBA_Grain V 5.2.2 has been implemented


 Heat transfer coefficient to workpiece can be defined depending on the
temperature

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 Support creep analysis in Forming GUI

Copyright © simufact engineering gmbh 26.03.2018 81


Result quality

 Improved contact status display when simulating workpiece sections

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14.0 15.0

Copyright © simufact engineering gmbh 26.03.2018 82


New features in Forming 15.0

Meshing improvements
▪ Trimming
▪ Cylindrical refinement boxes are
supported for surface-/tetmesher

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▪ Surface meshing
▪ Tetmeshing
▪ Sheetmeshing

Copyright © simufact engineering gmbh 26.03.2018


Preprocessing capabilities and model view
 Meshing improvements for trimming
 Cylindrical refinement boxes are supported for surface-/tetmesher

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 Meshing improvements in sheetmesh technology
 Meshing improvements for tetmeshing

Copyright © simufact engineering gmbh 26.03.2018 84


Preprocessing capabilities and model view
 Sheetmesh meshing improvements
▪ Sheetmesh meshing is now available for all application modules
➢ important for some cold forming processes
➢ important for some rolling processes
▪ Various improvements implemented to meshing algorithm
▪ Sheet meshing for planar surface was moved to main initial meshing dialog

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Meshing improvements - Sheetmeshing
 Sheetmesh meshing improvements
▪ Curvature divisions and min. element
size have been implemented

V 14.0 V 15.0

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The improved meshing of the radii probably generates more elements than in V14. You can reduce the
base element size or reduce the curvature division or specify a minimum element size. The entry 0 means
at the moment 1/5 of the basic element edge length.

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Meshing improvements – Sheetmesh/Hexmesh

 Sheetmesh meshing improvements


▪ Significant improvement of edge projection (avoidance of artifacts) especially
during trimming processes

 Hexmesh meshing improvements


▪ Hexmesher looks for new edges and performs further meshing with new edges if
meshing fails after trimming

 Thickness calculation significantly accelerated  shorter computing times

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Meshing improvements

 Ring meshing improvements


▪ Added volume control switch to ringmesher in GUI

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 Surface remeshing in FV simulations
▪ Meshing files are written in binary format  less I / O, computing time shortened
compared to V14

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Meshing improvements

 Meshing improvements for surface-/tetmeshing


▪ New MSC Tetmesh library has been implemented
▪ Improved meshing quality (avoiding inside-out elements)
▪ Improvement of the projection of the nodes on the dies after remeshing

▪ New default values for surface-/tetmeshing


➢ Minimum element length: 0 (1/5 base element size)
➢ Edge angle: 60°
➢ Curvature divisions: 12

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Meshing improvements

 Important note:
▪ When the project is rebuilt, the default values become active immediately.
▪ For old projects (for example V14 projects), the old input values are used first. It
is recommended to update the project in the process type dialog. After that the
new default values will be used. In the initial meshing dialog, the mesher type
should be changed once and then back again, then the new values will also be
used. Alternatively they can be entered manually.

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Meshing improvements

 Near-contour meshing can be assessed in the initial meshing dialog using


the “shape deviation" criterion.

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New features in Forming 15.0

Result quality and calculation time


▪ Segment-to-segment contact with
DDM
▪ Rigid dies with heat conduction as
load-controlled bodies are supported

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Result quality and calculation time

 Speed and robustness of the solver have been improved


 Segment-to-segment contact with DDM is now supported. There are no
limitations concerning S2S and DDM anymore
 General contact properties in the input deck have been reworked, especially
for S2S contact
 Improved convergence behavior when using segment-to-segment contact
combined with die spring or generic spring
 Rigid dies with heat conduction as load-controlled bodies are now supported
 Start script (used to start calculations on remote Linux machines) can now be

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selected directly in the job submission dialog

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Result quality and calculation time
 RET mesher technology (FV) was removed
 The Pardiso Direct Sparse solver is the new default solver for 2D simulations
 The Pardiso Direct Sparse solver is new default solver in 3D simulations where the
Multifrontal solver was the default solver in the past (process-specific *.ini files
adjusted)
 Error message appears if a project is about to be opened that is being used by
another user

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 Set default value for separation stress for S2S contact
 Improve contact settings for def.-def. contact

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New features in Forming 15.0

Material data

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Material data
 Reworked international norms for some materials
 Added the possibility to define the AWS norm for alloys
 Added possibility to define creep properties for stress relief heat treatment
simulations
▪ Added creep laws are power law, steady creep law and hyperbolic creep law
 Reworked some materials and added creep material data for some of them
 Improved usability of the flow curve scaling dialog
 Added database for most coatings for resistance spot welding
 AC1 and AC3 temperatures can be defined (for information purpose only) for a
given material

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 Add a dissipation factor to all material files
 Rename material group "Tool steel“ in “Tool material”
 Rework material files standards

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New features in Forming 15.0

Data exchange
▪ Magmasoft interface
▪ Flexible CSV interface
▪ UNV export improvements

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▪ VRML export

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Data exchange – Magmasoft interface

 Import selected results from casting simulations with Magmasoft


▪ Imported results are geometry, temperature and relative density

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Data exchange – Magmasoft interface
 Export of casting process simulation results of MAGMASOFT ® for simulation
of further processing with Simufact Forming

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Data exchange – Magmasoft interface
 Procedure to export of casting process simulation results
▪ As a prerequisite a casting process simulation has been run and all relevant results are
available. The export requires a license of the module MAGMA link and an installation of
MAGMASOFT ® Release 5.4.
▪ First of all the MAGMASOFT ® user exports the material groups that are relevant for later
forming simulations to STL geometries – relevant are for example casting and feeder.
This is done in the geometry perspective via CAD export.
▪ In the FEM export menu the user chooses the Simufact output format. As an input he
chooses the generated STL file.
▪ Then the software requires the user to assign the available parts of the STL geometry to
casting and feeder material.
▪ After that the user has to decide on the particular results to be exported. All results of
casting process simulations are available. Among them are all criteria and cumulative

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results as well as the results describing the casting process. There are no additional
settings of the software required.
▪ After pressing the „export“ button, the m2s file is generated.

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Data exchange – UNV export

 UNV export also supports elemental results (Gauss points)

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 Added the possibility to import flat and hierarchical BDF files that contain
several meshes. The file is then separated into several meshes.

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Data exchange – VRML export

 VRML export (wrl-file) available GUI

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New features in Forming 15.0

Documentation

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Documentation
 Completely revised introduction tutorial
 New introduction video
 Many new and revised infosheets
 Completely revised installation guide
 Many new examples in Simufact Demos
▪ New “What's new” category
 Updated tutorials

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Documentation
 Many new examples in Simufact Demos

▪ Induction heating
▪ Case hardening gas carburization
▪ New fold detection with FV
▪ Improved RSW functionalities
▪ User kinematics rolling curves
▪ MAGMASOFT import
▪ Mesh separation 2D

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Documentation
 Some infosheets should be listed here:

▪ KeyboardShortcuts_en.pdf (shortcuts in Forming GUI)


▪ Trimming_en.pdf (some hints for setting up a trimming process)
▪ TablePress_en.pdf (definition of table press)
▪ MeshSeparation_en.pdf (damage-based mesh separation)
▪ FormingControlStepControl(FV)_en.pdf (info about boosting in FV)
▪ ResultTransformation_en.pdf (info about result transformation)
▪ and many more…

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 The job submission dialog now always shows the infosheet button for the
infosheet about start scripts

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New features in Forming 15.0

Licensing, setup and configuration


▪ New MSC licensing

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▪ Improved setup

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Licensing, setup and configuration

 Supported operating systems


▪ Windows 7 (64-bit), Windows 8 (64-bit), Windows 10 (64-bit)
▪ Linux (only x86-64 architecture): solver only. Tested on Redhat Enterprise Linux
(RHEL) 6.7 and OpenSuSe 11.4

 Supported hardware
▪ 64-bit CPU (mainly tested on Intel® CPUs)
▪ 1 GB Graphics adapter with 32-bit color depth and OpenGL 2.1 or higher
compatibility
➢Intel onboard graphic adapters are known to cause various errors and are
strictly not supported

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▪ 1 TB of free disk space
▪ The size of required system memory depends on the size of models to be
calculated with 16 GB being a minimum for industrial use.

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Setup and configuration

 MSC Licensing replaces previous Simufact licensing system


▪ Licensing system from Flexera Software
▪ Prerequisite for sales concept MSC One
▪ Licenses are still created by Simufact
▪ The MSC license server is not included in the installation, please refer to the
release notes for further information on licensing
▪ Software must be downloaded from MSC Download Center (also Simufact
products)

 GUI and solver license feature are merged

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▪ Same license feature name will checked by GUI and by solver

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Setup and configuration

 MSC licensing replaces the previous Simufact licensing system


▪ Overview of existing licenses in the settings dialog

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Setup and configuration

▪ Application modules without license are disabled and greyed out


▪ Processes cannot be viewed, edited or started

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Setup and configuration

 Added the possibility to select components to be installed during the silent setup
 Last installation path is saved and preselected in the setup
 During the setup, installed versions of utilities and versions to be installed are
checked to avoid overwriting newer utilities with older ones
 Depending on installed redistributables and user access rights, the setup checks
if a working installation is possible with the current user account
 The IntelMPI® service does not have to be installed with user credentials
anymore

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 Removed IntelMPI® settings dialog from settings page

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Setup and configuration

 Restructured the settings window to achieve similarity with other


Simufact products

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Setup and configuration

 Added feature to global settings to manage the cache of the view


▪ It is recommended to increase the maximum size of graphics cache (e.g. 300 MB) for
improved performance when working on large projects

 Added the possibility to define rotation angles while rotating the view via
keypad and triad (compass)

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Setup and configuration

 Reorganized display settings including reset of default colors

 Added option to use radial gradient as background

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Setup and configuration
 Improved handling of projects stored in directories without writing
permission (message appears)

 Simplified the color settings


▪ Foreground color is always the inverted background color

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