1. Full Representation of Shop Floor Forging Practice Advantage by Increased Insight The Virtual Forging Shop MSC.SuperForge

2. How is Full Representation Achieved? Comprehensive Material Data Realistic Press Characteristics Accounting for Friction Accounting for Temperature Effects Accounting for Elasticity Automatic/Manual Positioning of Work Piece Handling of Multi-Stage Processes Powerful CAD Interface

3. Available in Database Form Select Material by “mouse-click” User-extendable Database Comprehensive Material Data Material Data depends on –work hardening temperature –strain rate

4. Realistic Press Characteristics Most Press Types Available User-extendable Database Most Press Types Available

5. Friction Friction Influences: –load and energy requirements –metal flow –pressure distribution –die wear Friction Models –Coulomb friction –plastic shear friction –combination User-extendable Database

6. Temperature Effects Needed to account for: –proper metal flow –die chilling during forming –thermal stresses during cooling Heat Transfer between Work Piece and Dies Heat Transfer to Ambient Heat Conduction within both Work Piece and Dies Heat Generation due to Plastic Deformation

7. Elasticity Effects Needed to account for: –deviation from desired shape (tolerances) –thermal stresses –proper die loads (die overclosure) Elastic-plastic material model

8. Positioning of Work Piece Influences Metal Flow Automatic or Manual Positioning –sliding is accounted for !!

9. Accurate Workpiece Positioning

10. Multi-Stage Process Modeling Automatic Transfer of Material Properties between Stages –stress, strain, temperature Transport of Work Piece between: –furnace and dies –different dies Intermediate Heat Treatment Handling by “mouse-click”

11. Powerful CAD Interface CAD Transfer via STL (Standard Triangulation Language) –standard format used in rapid prototyping techniques –commonly available in all CAD packages No ‘Finite Element’ Experience Required No Meshing STL

12. Why ? –enables precise filling of intricate die regions if metal flows into such regions –no user intervention required Able to capture small intricate die details by using: Resolution Enhancement Technology (RET) Advantages of MSC.SuperForge

13. Industrial Examples

14. Forging of an Automotive Cap pressure on tool MSC.SuperForge

15. Selected Reference Accounts