WHAT IS FREE/OPEN FORGING SIMULATION WITH CAE? – BENEFITS & CASE STUDIES

By utilizing CAE (Computer Aided Engineering) in Free/Open Forging, it is possible to visualize the transition of load and deformation through the forming process of materials and predict defects and failures that may occur during forming. This article will introduce an overview of “Free Forging,” the benefits of CAE analysis, and case studies.

WHAT IS FREE/OPEN FORGNIG?

Cold Forging is a forming method using simple tools whose surface is smooth or curved. The material is pressed with tools directly, by transferring and rotating material or tools while the surface is not enclosed.

This is a method in which the same part of the material is pressed multiple times, with the tools advancing each time. After this process, the material is formed into the designed shape.

This is mainly used to perform large components. The advantage of this method is that it does not need huge power for each forming process nor expensive equipment and facilities for the material sizes.

There are some of the popular methods in Free/Open Forging, such as Cogging, Upsetting, Radial Forging, and so on.

BENEFITS OF CAE ANALYSIS FOR FREE/OPEN FORGING

CAE analysis for Free/Open Forging enables you to visualize the transition of load, deformation, and temperature change of the material during the forming process, and predict cracks and other defects that can occur. By setting the appropriate anvil operations, you can prevent defects and failures in advance. As a result, you can reduce component production costs.

EXAMPLES OF FREE/OPEN FORGING SIMULATION WITH A CAE SOLUTION

Now, we’d like to introduce you examples of simulations using the CAE software DEFORM.

OTHER CASE STUDIES (Click on the images to visit the 3D animation pages)

You can read other case studies in Free/Open Forging Processes including Cogging, and GFM(General Forging Machine) Cogging.

Depending on the forming conditions such as multiple anvil operations, speed, and temperature, the forming geometry varies.

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  Hammer Forging Simulation The case study of the Hammer Forging simulation. This analysis enables you to check the strain accumulation during the hammering processes.

   

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  Cogging simulation The case study of the Cogging simulation with cogging template. This analysis shows you the temperature distribution during the cogging process.

   

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  GFM Cogging simulation The case study of the Four-die GFM Cogging simulation. By using the cogging template, you can easily set the conditions of the complicated GFM process to analyze.

   

CONCLUSION

Thank you for reading. We hope you found this article helpful.

By utilizing CAE, defects can be prevented in advance, and costs and lead times can be reduced.
In addition to the examples introduced here, the CAE software DEFORM has a wide range of functions to support designers, including other processes, data analysis, the design of an experiment module, and an optimization module.
Please feel free to contact us if you have any questions or concerns about product design and manufacturing.