COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES The simulation systems as computer support in design of non-cutting process request the choice of suitable principles and methods for the problem solution

OPTIMALISATION PRINCIPLES OF PROCESS DESIGN IN FORGING AREA  rapid and cost effective process design in preproduction stage,  application of forging process simulation to eliminate defect, predict failures in relation product – tools,  computer simulation (virtualisation). COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES The key technical problems in designing and developing of forging process: billet material(shape and size, chemical composition and microstructure), flowing properties under processing conditions (stress as function of strain, strain rate and temperature), tool - dies (geometry, surface conditions, material hardness, surface coating, stiffness), interface conditions (lubrication, friction, heat transfer, rigidity production rate force and energy characteristic

APPLICATION OF PROCESS VIRTUALISATION (In forging process the workpiece generally undergoes large plastic deformation and the relative motion between the deforming semiproduct and the dies’ surface is significant. ) COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES Key problems in modelling process :  properly selection of the coordinate system,  definition of the starting mesh (FEM),  definition of the mesh density ( mesh density should conform to geometrical features of the workpiece at each step of deformation),  definition of new mesh (remeshing) and the date interpolation from the old mesh to the new mesh in order to obtain accurate result,  definition of fixed displacement and points (nodes, …) of loading,  etc.

Geometric properties Material properties COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES Geometric properties :  thickness, /hrúbka/  cross section area,/prierez – plocha prierezu/  shear correction /v súvislosti so šmykom, zmena tvaru strižnej plochy/. Between key material properties it is possible to include:  young’s module, / Hook-E=б/Є (210000MPa pre oceľ, MPa=N/mm 2 )/  Poisson’s ratio / podiel merného tepla pri stálom tlaku a merného tepla pri stálom objeme /,  mass density, etc.

Examples of results visualization COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES Plotting style /formy vizualizácie/:  Contour lines (show lines along path of equal interpolated nodal values /interpolácia – metóda približného výpočtu/),  Contour bands (areas of equal interpolated nodal values),  Numerics (numerical values are shown at nodes),  etc.

CONCLUSION COMPUTER SIMULATION IN DESIGN STAGE WITH ASPECT TO NON-CUTTING PROCESSES  detail analyse of task (consider specific of non-cutting technologies)  choice of suitable software for simulation (Marc/Autoforge, SuperForm, Deform, etc.)  analyse of input dates (material properties, boundary conditions, etc.)  choise of optimal results presentation (plot, animation...) Conditions for resumption of optimal simulation result