Simufact (2)

The Hamburg-based software company Simufact Engineering now offers new versions of its simulation software Simufact.forming and Simufact.welding. Providing more functionality for a broader scope of application while offering a simplified usability - that´s the credo of the new software versions that are employed for the design and optimization of manufacturing techniques in metal processing.

With the new Simufact software releases, companies aiming to link various production processes in the process chain (from semi-finished material to finished component) have come closer to their goal of an integrated, cross-process approach in the simulation of entire process chains.

Simufact simulation solutions cover all essential production processes from forging to cold massive forming, rolling, sheet metal forming, mechanical joining, heat treatment, and welding. Also, standard interfaces allow customers a fast and reliable integration of Simufact software in their CAD/CAE environments.

A major step forward is Simufact’s integration of material data in the simulation of forming and joining processes: Simufact.forming 11 and Simufact.welding 3.1 not only offer a multitude of new, experimental material data; they also provide access to high quality analytical material data, thus ensuring accurate simulation results.
Simufact.forming 11 – professional forming simulation

Simufact.forming is an established simulation solution for forming and joining processes. The software release Simufact.forming 11 includes new modules for open die forging and ring rolling. Application-specific functionalities such as fully automated processing of a complete pass schedule in open die or radial forging, and the consideration of the manufacturer’s kinematic concepts in ring rolling, help the user to model and simulate all possible processes and conditions of these production processes.

Thanks to new possibilities in result-dependant, force and path controlled processing as well as an optional, method-related calculation of the structural transformation during forging, these new special modules have become indispensable tools for companies that use ring rolling and open die forging.

Release 11 is particularly interesting for joining experts, since it takes adhesives and high speed effects into consideration, which are gaining more importance in modern joining technology.

By offering improved possibilities for networking and evaluation, Simufact.forming 11 eases the engineer’s daily work in tool and process development. The feature “optimization” allows the comfortable testing of process options and ensures substantial time savings for the definition of the best process design. Highlights include the flexible description of thermo-physical boundary and initial conditions, and the automated reporting in pre- and post-processing.

The efficient simulation of realistic heat-treatment processes provides for more flexibility and realism in mapping the process chain – before, during, and after the forming process.
Simufact.welding 3.1 – more than welding simulation

Simufact.welding 3.1 enables the simulation of various welding methods. Cutting edge solver technology and a user friendly overall concept allow for an effective calculation of welding sequences and a realistic prediction of component distortion, also taking into account microstructural transformations.

The coupling of Simufact.welding with Simufact.forming is a new functionality linking different process chains. Thus, processes taking place before or after welding can be efficiently integrated in the numerical approach. Easy data transfer allows for consideration of the forming history and the strength analyses of the simulated welding seams.

The calculation of phase transformation and phase volume fractions, as well as the automatic mapping of weld filler metals complement the new features. Simufact.welding 3.1 provides the user with a simple and comfortable modelling of more complex welding seams, even the simulation of multi-layer welding is now possible. Last but not least, the new release offers an improved calculation of contacts for process related gap formation during the welding process.

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Simufact Engineering GmbH, a leading provider of software and services in the area of process simulation, announces the availability of its new simulation environment Simufact.welding for the process optimization of welding applications. Simufact.welding supports welding specialists and engineers in the layout and test of welding processes. Simufact.welding is easy to use and therefore, virtual process design and optimization can be applied in close relation to production for the first time ever. Simufact.welding will be available in June 2011.

The use of Simufact.welding permits an accurately timed control of several robots, an easy modification of welding sequences, speed, heat input, stop times, or fastening devices. Quick evaluation of process variants by change of welding parameters leads to systematic optimization of fusion zones, heat affected zones, residual stress and distortions. The software provides extensive tools for reporting, among others for the display of distortion, temperature distribution, residual stresses, curve progression of physical factors on fixed measuring points as well as several export interfaces. Most different ways of description such as dynamic cuts through the welding seam, flexible views and detailed x-y-diagrams enable a quick and efficient analysis of the welding process.

The functions of Simufact.welding at a glance:

• pre- and post-processing within one GUI
• no data conversion
• fast presentation of results
• result evaluation simultaneous to computation
• interactive graphical sequence control of robots and clamping tools
• section views of all result values
• “Weldmonitor” (trip to all welding seams in a 2D section)
• measuring point diagrams for comparison with test welds
• progress indication of calculations with access to already calculated results during the analysis
• context support for all input areas
• interface to RoboCad as well as export interface to robots
• Dual Solver Technology: optimized MSC.Marc Solver, IFE WELDSIM Solver
• different heat sources (Goldak model, cylindrical volume sources, surface heat sources with Gauss
• comparison of simulation results with real micro sections through “Weldmonitor”- function
• real stress conditions
• welding paths in real speed, direction and inclination

“Modern industrial welding processes ask for a high degree of process security ", says Dr. Hendrik Schafstall, managing director Simufact Engineering GmbH. "Simufact.welding supplies information which normally could be gained via experiments only and with an unreasonably high effort – or even not at all. Error sources can now exactly be identified. This permits a structured approach for part and process optimization."

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