Isabella Mazza, Ergolines Srl | M. Turchetto, ESTECO SpA | C. Persi, Ergolines Srl | A. Santoro, Ergolines Srl | S. Spagnul, Ergolines Srl
This paper describes the activities of ESTECO and Ergolines for the iCAST project, funded by Regione Friuli Venezia Giulia under the POR FESR 2014-2020 call. The project is part of the “S3 - Smart Specialization Strategy” area (metalworking sector), in the framework of the development trajectory dedicated to Numerical modeling technologies of processes and products.
Ergolines and ESTECO team up to elaborate a new technology for ‘assisted solidification’ of steel in order to improve the quality of the final product. To achieve this goal, they are carrying out research activities in the field of modeling, simulation and numerical optimization of key parameters of the process and plants.
Moreover, with the aim of defining an innovative methodology for collaborative design in this field, ESTECO will customize its state-of-the-art technology, and in particular modeFRONTIER desktop software to include numerical solvers and models in the logic process and the web-based enterprise platform VOLTA to distribute computational load on the network resources, to include experts and non experts in the engineering process.
Numerical simulation of electromagnetic stirring in steelmaking industry
Francois Bay, MINES Paristech | Elie Hachem, MINES Paristech
Electromagnetic stirring is widely used in casting industry in order to control the flow of molten metal and the final properties of the piece. Stirring allows keeping the temperature uniform and avoiding segregation, leading to a better quality of the final product. In continuous casting, it also decreases the turbulence in the melt, decreasing the possibilities of a breakdown. However an efficient design is not easy since experimental data are difficult and expensive to obtain and analytical models are way too simplified to be used in industrial applications. Hence, numerical simulations are the most common tool to support the design process; the main disadvantage is the high computational cost required to perform the simulation which is strongly multiphysical. The aim of this work is to develop a set of numerical tools able to accurately model electromagnetic stirring applications with a low use of computational resources.
The numerical scheme used for the computation is based on the “Two Mesh Two Solvers Approach” discussed in [1,2]: the electromagnetic fields are solved by Matelec® (developed in the Lab) on a specific mesh, while the thermomechanical analyses are carried out using Thercast ® using a different mesh and domain. The mechanical fields are solved using a stabilized VMS method enhanced with anisotropic mesh adaptation . The common coupling scheme (“one way coupling”) has been enhanced and a weak-two-way coupling strategy has been implemented between the electromagnetic and the mechanical solver. Strong coupling has been judged non-efficient because it does not lead to a significant increase in the accuracy and because it is computationally too expensive for industrial applications.
The Lightweight Forging Initiative & Contribution of Simulation Software in the Development Phase of high-strength Components
Hans-Willi Raedt, Hirschvogel Automotive Group | Patrice Lasne, Transvalor S.A. | Helmut Dannbauer, Engineering Center Steyr GmbH
Modern technical systems often involve high-performance forged components. Their key role is based on the one hand on their enormous load-bearing capacity required for the transmission of high forces and momentums. On the other hand, it can be observed that in times of increasingly scarce resources there is a growing demand for efficient industrial production processes – as is the case for forging. Especially in the automotive industry, increasing demands with respect to lightweight design and power density call for the ever more intensive optimization of components, which requires the careful matching of alloy, component geometry and the many parameters along the entire design and manufacturing process chain. By involving the supplier in the product development process and in engineering partnerships early on, favorable conditions are created for finding economical solutions that benefit both parties.
Benefits of simulation to define and optimize metal forming processes
TRANSVALOR software have been used for over 30 years in forging industry to design and improve solutions. Its wide range of applications enables the user to simulate all operations, which makes it an indispensable tool for understanding and mastering metal forming processes. The presentation aims at showing several applications focused on the benefits of Forge® and ColdForm® to improve the quality of products and processes.
This full presentation is not available
Global approach of Transvalor on process simulation
TRANSVALOR has recently changed its approach from software editor to complex process simulation solution provider. Around the main software, Forge®, ColdForm® and Thercast®, new embedded tools and separated programs have been developed to manage microstructural evolution (Digimu®), welding processes (Transweld®) and additive manufacturing (Additive 3D®). In this session, such evolutions will be presented , with specific focus on complex issues of the industrial world of tomorrow.
This full presentation is not available
Raffaele De Scisciolo
Simulation assisted feasibility and technical realization to meet customer requirements
Marcello Gabrielli, EnginSoft SpA
The world moves fast and the only way to lead the challenges is to stay aligned with technology and take advantage of it. Even in heavy industry the shortest development time is become one of the key driver of the success and one of the key driver of the time reduction is the capability to have data in advance using the FEA to simulate product and processes. In this presentation is reported the Berco’s way forward to adopt and take advantage from computer aided simulation and give some ideas about the goals we achieved. Thanks to this approach and the continuous support of EnginSoft, on the processes side we were able to achieve some golas as reduce time-to-market from 6 to less than 2 weeks, build dies only after virtual validation, save 15-30% of steel, increase robustness of some processes. In this field of application of the simulation, new challenges are induction heating, ring rolling, grain-size and metallurgy prevision. On the product side the structural FEA simulation of the components is critical due to several complex contacts between parts in the undercarriage assembly: new approaches used by EnginSoft System Dynamics Team have been presented, where multibody simulation of the full vehicle interaction with the terrain has been used to detect the loads to be applied later in the FEA of the components. Residual stresses linked to production process have been also considered. Optimization techniques for FEM calculation, but also for mass reduction, have been used also to find the best component shape linked to his structural function.
Forging performs design and inverse analysis for friction coefficient calculation by means of FORGE optimization tool
Ángela Mangas, Fundación TECNALIA Research & Innovation
Forge NxT allows optimizing forging processes with its optimization module. The use of this module automates long and repetitive data setup and parameter selection to save human work and to speed up process design. Optimization tool is mainly used to look for the most suitable preform shape and/or the best geometry of forging dies by means of analyzing several process parameters (billet temperature, friction coefficient,…) influence. But the optimization tool can be also used for identifying the experimental values of different process parameters. The presentation will show some application cases to display the capacities of this tool.
First, two cases where the forging preform is obtained by optimizing its geometry will be showed. In the first case, the geometry is built directly in Forge with the “Initial Mesh Creation” tool and in the second case the geometry comes from an external CAD software (Pro-Engineer). Afterwards an inverse analysis to obtain friction coefficient from laboratory ring compression tests will be presented.
Laetitia Pegie, Customer Service Department Director Transvalor
Antoine Navarro, Product Manager Transvalor
First edition of a Transvalor Steering Committee in Europe; Italian users will see the forthcoming evolutions of Transvalor software, such as new processes, new features and mid and long term R&D activities. A roundtable will follow, where users’ suggestions will be welcomed in view of further improvements of the programs. Dedicated sessions will be organized on request, and in relation to on specific reserved issues, at end of the meeting.