M A T E R I A L F O R M I N G S I M U L A T I O N

2D & 3D METAL COLD FORMINGSIMULATIONSOFTWARE

COLDFORM®

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A very broad application scope

Significant cost and productivity gains

COLDFORM® meets the needs of industrialists in many fields:• design and manufacture of parts formed from sheets ranging

in thickness from moderate to high (clockmaking, precision mechanics, etc.);

• design and manufacture of assemblies: screws, nuts, bolts, washers, etc.;

• design and manufacture of motor parts: shafts, gears, rings produced by ring rolling, cold-formed parts.

The benefits of COLDFORM® can be observed at all steps in your activity

During the R&D phase, for the development of innovative or complex products:• lifting technological barriers to innovation,• reducing design costs,• reducing development costs,• making products more reliable and reducing technical risks,• building your company’s knowledge and expertise.

During the production phase, to optimize the various forging steps and improve manufacturing processes:• reducing prototyping and workshop testing related costs,• reducing the quantities of materials used,• optimizing production processes,• extending die service life.

During the negotiation phase, thanks to production cost control and improved schedule reliability:• considerably shortening the design phase,• reducing material costs,• reducing time-to-market,

Simulation of the threadrolling process and von Mises

stress estimates.This simulation is part of

the complete screw forgingcalculation, meaning thatthe calculation of residual

stress takes into account theprevious forging steps.

Riveting: residualstress prediction

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The 4 steps in the forgingsequence for a standard automotive sector part.

(Hatebur Umformmaschinen AG,

Rapid computation for precise results

COLDFORM® allows you to optimize your forming operations and to precisely predict:•the exact geometry anddimensions of the definitive parts, taking

spring-back into consideration;• material yield throughout the forming sequence;•possibleunderfillandfold;•fiberingandstressdistribution;•markingandmonitoringofspecificsurfaces,suchascuttingsurfaces,fromtheinitialbillettothefinalshape;

• damage and rupture criteria;• residual stress distribution;• etc.but also material displacement, plastic deformation, temperature and allotheruser-definedvariables.

An exhaustive database and a plethora of modelsCOLDFORM® contains a rich materials database:• more than 200 steel, aluminium and brass references,• ability to create material data from the mechanical properties provided by the manufacturer (yield strength, tensile strength and elongation at break).

The software provides models for materials with standard and anisotropic behavior, with a vast range of lubrication conditions and theabilitytodefineseveralfrictionconditionsforthesamedie.

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Final geometry of the stamped part.Only a suitable mesh can enable the crumplingofthedefinitiveshapetobeaccurately represented.

Cold forming of an automotive part on athree-pass machine, taking press stiffnessinto account.(K-Won, Korea)

Some examples of cold forming processes simulated by COLDFORM®:

• Closed die forming• Stamping• Cutting, shearing and piercing• Orbital forging• Hydro forming• Extrusion process• Riveting and crimping process• Incremental forging• Thread rolling• Ring rolling

Bevel gear forgingsimulation:

contact analysis at varioussteps in the process

(contact surfaces areshown in blue).

Stamping a 115 mm highand 0.8 mm thick aluminium part.(K-Won, Korea)

Stress distribution ina 7-component assembly.Stress analysis is performedon all 7 components.

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Prediction of press force required to forge a screw using a mechanical press

Stress distribution within the top die used to forge a bevel gear

Validate your equipment choices, extend die service life and reduce die costs

COLDFORM® allows you to validate your equipment choices by precisely determining the press required to form your parts. Its database contains models for:

• mechanical presses,

• hydraulic presses, knuckle presses,

• orbital forging presses,

• circular rolling mills.

COLDFORM® allows you to analyze die strength in order to extend their service life. The software can compute stress distribution within the die, along with deformations, wear, temperatures and damage at any time during the process.

COLDFORM® can perform rapid analyses consisting in applying the stresses obtained during forming process calculation to the die.

Moreover, COLDFORM® is capable of performing coupled part/die computations, giving extremely preciseresults.Itisalsoeasytodefineprestresseddiesandtostudytheeffectsofinterferencefit.

COLDFORM®, the answer:

> to your quality demands,

> to your cost control requirements,

> for reducing your lead times.

Analysis of the 7 dies used to forge an automotive part.Thiscalculationtakestoolinterferencefitintoaccount. von Mises stress is represented for all dies.

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COLDFORM® application exampleThe following part is produced in four steps, with annealing operations. COLDFORM® simulates and chains each step in the process in order to study the complete forging sequence.

The simulation precisely computes part changes during the forming steps. The following illustration shows a comparison between the actual part and the simulation result.

In addition to predicting the overall shape, COLDFORM® also reveals any local defects.

An initial examination of the results enables contact and non-contact zones to be easily identified,alongwithallothergeometricimperfections.Thestudyofthesecondendofpartshows the extrusion length differences and defects in the orientation of some surfaces. Thus, the preliminary study of the forging sequence using predictive simulation software such as COLDFORM® allows you to anticipate defects and to optimize a forming sequence prior to conducting production line tests.

Elliptical contact area

S-shaped line

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Parc de Haute Technologie694, avenue du Dr. Maurice Donat 06255 Mougins Cedex - FrancePhone: +33 (0)4 92 92 42 00 Fax: +33 (0)4 92 92 42 01Email: services@transvalor.comwww.transvalor.com

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TRANSVALOR has been certified ISO 9001: 2008 by the Bureau Veritas Quality International (BVQI) for the development, industrialisation and licensing of computed-aided engineering software and related services. This certification shows the will of TRANSVALOR to progress and to answer better its customers’ expectations.

TRANSVALORisaworldleaderforsimulationsoftwareinthefieldofmaterialforming.Thanks to its continuous R&D policy, TRANSVALOR software remains constantly at the cutting edge of technology.

More than 500 customers worldwide, including major players in the automotive, aeronautics and energy industries, along with several prestigious universities, trust TRANSVALORanditssoftware,thusguaranteeingtheirefficiencyandreliability.

A premium service based on 30 years of experience

Transvalor is also a team of experts dedicated to your simulations

Your requirements correctly understood

Unique means available to you

In order to create your service, we provide:

• TRANSVALOR’s expertise in simulation

• the most recent software versions

• latest-generation computational resources

Results analyzed and interpreted

Advice and training

Through exchanges with your specialists, we are able to determine your numerical simulation requirements in order to precisely determine the service that we offer.Our offer will closely meet your needs in terms of lead times, budget and expected results.

Throughout the study phase, we keep you informed of progress. Upon completion of the study, we present you with our main conclusions during a Web conference.Uponrequest,theresultsfiles,alongwithanymeansrequired to analyze them, can also be provided.

TRANSVALOR also proposes assistance days to ensure that you are fully abreast of all aspect involved in your study.Tailored topical training may be provided on your premises, on TRANSVALOR’s premises or by Web conference.