Problems solved by QForm

Die Filling / Under FillLapsFlow Through DefectsGrain FlowInstabilityTemperatureLoadVentingBillet PositioningDie StressDie WearDie Deflection

Die Deflection

QForm can show die deflection based on the forging loads applied through the workpiece in both 2D and 3D simulations. This allows the user to see where the forces are greatest within the tooling. A magnification factor can be applied to make the deflection more visible.

die deflection in 3D tooling at a 100:1 magnification factor

In 2D tool simulations the inverse profile of the deflection can be exported to CAD so you can build your dies to compensate for the deflection. For instance in the following forging sequence:

A tool simulation of the end of stroke showed that the die deflection was greatest at the center of the die.

The inverse of the die deflection was exported to cad and the forging with the new die showed much more even deflection that was well within the design tolerances.

Coupled simulations

QForm version 7 can perform coupled simulations that simulate the die and the tool together and show their influence on each other. QForm 7 can perform coupled mechanical as well as coupled thermal simulations. In the following example you can see the advantages of a coupled mechanical simulation.

This forging was run with and without a coupled mechanical simulation.

-----Non-coupled simulation----------------Coupled simulation------

You can see the difference in the flash. In coupled mechanical simulation, the die deflects during the forge stroke so that there is more volume for the workpiece to fill. Therfore the flash does not extend out as far in the coupled mechanical simulation.