FORGE-Auto
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SOLUTION FOR THE AUTOMOTIVE INDUSTRY

Crankshaft folds/laps metal flow quenching heat treatment reducer rolling flash trimming yield improvement material cost reduction automatic optmization power train rotary swaging net shape transmission chassis forging load central looseness

We, at Transvalor, fully understand the challenges of supplying forged automotive components. Over the past 25 years, FORGE® has been the perfect solution in predicting the usual shop floor issues and to help designers, metallurgists and R&D engineers overcome their technical issues and optimize their processes. is the solution to: • Design First Time Right forging sequences and dies • Reduce design cycle • Minimize real scale try-outs • Increase yield • Extend die life • Optimize and consolidate quotations.

FORGE® is a comprehensive simulation software to validate and optimize the entire forging sequence from pre-forming stages up to heat treatment analysis. Accurate prediction of the geometry for all stages of a steering knuckle Bharat Forge Ltd., India. FORGE® is the solution to increase productivity and reduce costs

FORGE® makes it fast and easy to validate the complete forging sequence, for any type of component, chassis, transmission or powertrain parts and predicts: Underfillings and excess material Folds/laps Grain flow to localize un-deformed areas or internal folds FORGE ® allows very accurate predictions of material flow including underfillings such as shown in this picture (underfillings in red). Folds/laps are identified in red in this simulation of a steering knuckle. Prediction of the grain flow of a one cylinder crankshaft and comparison with the real part: the localization of the...

Improve your forging sequence & deliver high quality components with the unique features of FORGE® Central looseness tracking. The position of the central looseness of a crankshaft has been tracked during the complete forging process and is represented in the final shape. Shear surface tracking of the initial billet up to the final geometry. Localization of the shear surface tracking of the initial billet of a connecting rod. Shear surface is represented at different stages: end of reducer rolling, end of edger, end of finisher.

Component distortion during trimming for high accuracy simulation. Trimming of a commercial vehicle component is represented here. With FORGE®, the distortion generated on the part by the trimming process is taken into account. Cold formed netshape components by rotary swaging process. This application illustrates the cold forming of a hollowshaft by rotary swaging. This CPU demanding simulation is achieved thanks to the use of the bi-mesh method. This technique allows significant CPU time reduction by using two different meshes for thermal and mechanical solving. Highest speed-up with...

Increase die life and optimize equipment with the FORGE® fully integrated die analysis feature FORGE ® can accurately predict stress, abrasive wear and temperature distribution in the dies as well as forging load and equipment deflection. Fatigue crack initiation in the die cavity. Crack initiation in the die cavity of a yoke connection. HirschVogel Umformtechnik GmbH Abrasive wear on a punch using Archard law. Hatebur Umformmaschinen AG Actual & Simulated Die Wear. Forging load prediction in the finisher stage.

Unique competitive advantages of the FORGE® die analysis feature FORGE ® offers unique features to calculate: Die temperature at a steady state Thermal and mechanical analysis into the dies (including die deformation) at any time of the process with a fully coupled or uncoupled computation Pre-stressed dies Spring loaded dies Extensive forming equipment kinematics Mechanical press, hydraulic press, screw press, hammer, knuckle joint press, direct drive press, orbital forging press, forging machine, ring rolling mills, flow forming mills.

CASE STUDIESPioneer and market leader in automatic optimization CASE 1 • The objective of this automatic optimization is to minimize the cut weight in order to save material. The forging sequence of this steering sector shaft is made of 5 stages, 3 preforms, blocker and finisher. The input material is a rectangular billet (RCS). Transitions between each stage are managed automatically by FORGE®. The parameters to be optimized are the billet length and width. The optimum billet dimensions were automatically found by FORGE® resulting in a 9% saving in material. Flash pattern before (in red)...

Unmatched Flexibility FORGE® provides the highest flexibility with unlimited access to the Graphical User Interface for 64-bit pre and post processing. License fees are related to the number of computer cores regardless of the number of users. Extra flexibility benefits are: Job scheduling 2D and 3D automatic transitions between stages Dynamic token allocation across multiple and remote sites (Floating license) Solver support for up to 64 cores in parallel (one simulation can be executed on 64 cores concurrently) FORGE solver Token borrowing

Transvalor, leading Software Editor of Material Forming Numerical Simulation for extensive hot, warm and cold metal forming, COLDFORM® for cold metal forming THERCAST® continuous casting, Rem3D® for plastic injection & composites molding. Transvalor products provide the manufacturing and engineering intelligence to a wide range of industries Automotive, Aerospace, Energy, Medical, Oil and Gas and many others. Transvalor success comes from a comprehensive expertise of the forming processes and an unyielding capability to innovate. The value of Transvalor Material Forming Simulation Solutions...