Die Filling / Under Fill
Insufficient die fill is a common problem in forging. It is also important to understand the progression of die filling to know how the material flows within the die cavity. QForm allows you to see the progression of die fill throughout the forging cycle in an intuitive and easy way. Prior to simulation this sort of information was only possible with progressive forging trials.
2D simulations show a cross section of the forging so die fill is simply seen as a gap between the workpiece and the die. In 3D simulations, QForm shows the area of die contact on the workpiece with a blue color so it is very clear what areas are in contact with the die.
The following is an example of using the visualization of die fill to reduce the material used in a forging. The customer produced this connecting rod with a rolled preform. With QForm they experimented with reducing the diameter of the preform to reduce their material cost. The end results were they got adequate die fill and reduced the billet weight by 12%.