Simufact.forming 11.0

Transcription

1 1. General information Simufact.forming 11.0 Simufact starts a new strategy with version 11.0 to capture future requirements and to deliver the best-in-class solutions. Simulate component-property oriented manufacturing Obtain accurate solutions Higher robustness and speed Support automatic optimization Enable process chain simulation All project files have a version number (11.0) and can be used only with Simufact.forming 11.0 and later versions. They cannot be opened with older versions. The material database is included in simufact.materials and is installed as an independent product. All material properties for all programs and material models will be stored and visualized. Supported platforms Windows 7, Vista, XP: 32 and 64 bit ATTENTION: - With the next release of Simufact.forming we will no longer support Windows 32bit versions - With the next release of Simufact.forming we will no longer support Windows XP and Vista Linux: 64 bit (GP GUI and solver only) 2. New and improved features in Simufact.forming 11.0 Many changes have been made in the structure of the program We added a new universal material program and interface We continue to improve the ease of use The computation time is getting shorter More design variables are supported Simulation process and results are documented and reported More and better material data and models can be utilized More flexibility was added in setting up a model Realistic process kinematics can be modeled We improved meshing technologies 1

2 We improved postprocessing capabilities We can simulate heat treatment during and after forming for better prediction of the residual stresses We support SixSigma for better serial examinations Processes can be optimized automatically Multiple deformable dies can be simulated with parallelization for the finite element method using domain decomposition We improved our online help, tutorial and added more demo & examples We can better support research institutions and universities We improved the license system License path is stored in an INI file License usage statistics can be stored in a file 2.1. New material interface (FV/FE) 2

3 A new material database is embedded in all programs and its interface can also be used as a stand-alone program. Material data are stored independently based on the release version. It is flexible, innovative and based on the modular concept It supports more material data and models Most of the important properties are stored including the chemical compositions All material information is saved in a single file (*.umt) which can be used for both the FV and FE solvers. Material data can be selected from different standards (AISI, JIS, DIN, EN) New interfaces were created to transfer data from other databases Matilda (*.gmt) JMatPro (*.jmt) also for heat treatment data GP format material file (*.mat) Support for tables and analytical functions of flow stress curves Analytical material functions can be combined for the different temperature ranges User can define material models with up to 16 parameter constants or tabular values Flow stress curves can be digitized from images Anisotropic plasticity can be used based on Hill or Barlat models Support of CCT and TTT curves for heat treatment simulations, including Data for phase changes from Austenite to all phases Volume change Latent heat Trip effect Accurate calculation of the distortion and residual stresses Support data sheet for all material information Support of rigid-plastic material model for tetrahedral element 157 Support purely elastic stress analysis for tool and die deformation with tool steels 2.2. Improved preprocessing Support New file/open file without closing previous file Projects can be saved and reused as templates Process menus were redesigned Support the following new process types Rollforming 2-D DXF file can be automatically imported and converted into 3-D geometry with rotational axes It can be used to convert any 2-D DXF file into 3-D geometry Offset is added for each station Automatic mesh generation is based on the final workpiece shape 3

4 A full model can be set up in minutes Heat treatment (optional) Control of a heat treatment cycle Improved process types Punching & Trimming With multiple dies Based on direct punching/trimming or using a Boolean operation Works with table kinematics For FE solver, trimming can be done - Before forming - During forming - After forming Distinguish between 2D planar and axisymmetric models in main process dialog Define solver for FV simulation in main process dialog High-order solver is the new default setting and can be changed in the INI files (~\simufact\forming\11.0\sfforming\settings\*.ini: IsProcessFV=0 StandardSolver, IsProcessFV=1 HighOrderSolver) "Standard solver" can be selected optionally Step size control is set based on the solver type Define number of required dies Automatic renaming of the dies, using the name of the imported geometry Fast setup of the model with name from CAD system Or use imported dies and create dies automatically Possible to comment with line break CAD interface supports latest version CADfix 8.1 SP2 Many IGES defects are fixed Support latest CAD versions ( Native Interfaces CATIA V5/R22 CATIA V4/ 4.1.X, 4.2.X Pro/Engineer Wildfire 5 and Creo V1.0 SolidWorks 98 to 2012 Siemens (Unigraphics) NX1 to NX8 Inventor up to 2012 Neutral Interfaces ACIS R21 IGES 5.3 STEP AP203 & AP214 Parasolid V22 VDASF 2.0 STL 4

5 Possible to expand 2D (planar) results into 3D Create a rounded cylinder as an initial geometry Switchable component legend in the model window Improved filter to show processes in the process window The menu window can be dragged outside the GUI Faster management of the processes Support new feature to scan and digitize curves They can be saved in a global database and be selected from a list Support tables used for Heat transfer coefficient to the environment depending on the temperature Heat transfer coefficient to the workpiece depending on the contact normal stress Emissivity depending on the temperature Heat transfer coefficient can be computed automatically based on the normal stress of the used material Support new initial condition object for workpiece and deformable body for Grain size Relative density Phase composition (Austenite, Ferrite, Bainite, Pearlite, Martensite) Improved tool and die positioning apply displacement to will now work for both translation and rotation move one body to the right position and apply this to all other tools Rotation around rotational axis of the part Rotate part around its own rotational axis if it is defined Improved process control Backward motion as % of stroke Define release order of moving dies Use stabilizer for instable processes Improved step control for cooling/heating processes based on a max. temperature change within an increment Output particles every n-th increment to allow a continuous output Write an additional ASCII file (*.trk) with same frequency Modified approach loadcase for table presses Will use the real time and will move all bodies until one body touches the workpiece, then all movements will stop Particle improvements Define particles for workpiece and deformable or heat-conducting dies Support more output result types Improved friction implementation in FE Support of µ and m in combined friction model Improved IFUM friction law for FE Improved solver implementation in FE Stroke-dependent output for energy-based presses in FV Improved THS output for energy-based presses in FV 5

6 Increasing the number of blows for multi-blow jobs during restart is possible Improved volume control for high-order and standard solver 2.3. Improved kinematic capabilities Define springs between two rigid bodies Spring will be locked when distance is equal 0. The two rigid bodies will then be coupled and move together with the movement of the velocity-controlled body Improved cogging module faster supports new features New kinematics for rotary partial forging New kinematics for shell forging Improved ring rolling module Faster New control algorithm for mandrel and axial rolls Movement of tools can be switched from displacement-controlled to force-controlled Supports new segmented mesh refinement Improved kinematics for radial forging User-defined kinematics via interface, for flexible implementation of new kinematics by users: Menu is defined via *.xml file Menu is shown in the GUI based on this information Parameters are written into *.kin file which is read by the solver and passed to the subroutine sfukin.f Improved remote control system Improved remote control system to run the simulation on different computers or clusters in the network User can choose on which machine he wants to start the simulation Remote server will control folder structure independently from client User can start job under different user name Use of user subroutines or special executable is supported Works on Windows and Linux computers Result files are merged on server for DDM Files are automatically synchronized, and returned from simulation server to local user machine for postprocessing (no Windows network drive needed anymore) Settings can be defined in a profile manager Define host name and user with password

7 Installed software on the server will be shown automatically 2.5. Improved postprocessing Show real meshes with results (Hex as Hex, Quad as Quad) Measurement on meshes New result types Area change External pressure Phases Show planar 2D results as real 3D geometries Integration point values for FE are stored at the nodes of the mesh Better representation of gradients inside the parts Improved curve plotting Compare different processes Use experimental data for comparison. Import is based on CSV file format Improved cutting algorithm & cutting dialog Improved Simufact.mesh and ARC file analysis (convert ARC, THS to ASCII) Selected processes with results can be stored from a project under a new name 2.6. Improved DDM capability for FE solver No limitations for DDM in 3D Support DDM in 2D for HT processes Multiple deformable bodies on multiple domains Support particles, flowlines and springs Merging of the results during simulation parallelized Different domain decomposition methods 2.7. Improved documentation for pre- and postprocessing Process report will include information about Hardware System configuration Computation times Detailed information about the calculation behavior (separations, cycles, remeshings etc) New post report with user-defined images and comments Easy to define Can be used as a template for other processes or variations with the same limits and time increments 2.8. Improved meshing capability 7

8 Redesign of the meshing menus FE Improved AdvFrontQuadMesher (also GUI) Improved HexMesher Improved Tetmesher Improved Ringmesher Improved Sheetmesher Improved cylindrical Hexmesher with automatic determination of the center of the rotation axis Adaptive meshing for Hex and Solid-shell Based on gradients Based on penetration Based on contact In a box FV Improved surface mesher Same meshing dialog as FE RET and surface mesh options for FV now accessible in meshing dialog New mesh criteria to reduce meshing times Faster meshing 2.9. Support for R&D (user subroutines (FE)) Support state variables for nodes and elements Pass state variables in multistage jobs Store user-defined parameters in the project for use in solver Integer, real variables and strings Activate special routine in the solver umotion etc. New utility routines get_bodyid get_material get_nodvar get_elmvar New material interface user_fstress for flow-curves New optimization module Aim of optimization is to find values for a set of input parameters which describe a particular problem using numerical methods. It requires: An objective function: The objective function is the mathematical formulation of the optimization task. Normally it is written in a form where its minimum solves the optimization problem. At least one design variable: These variables are modified by the optimization algorithm until the objective function is minimized. 8

9 Termination criteria: criteria to decide when to stop the optimization loop Objective function reaches zero Values of design variables remain stationary through subsequent iterations Objective function is stationary (does not depend on further changes of design variable values) Optionally: Constraints like minimum/maximum admissible values for design variables Boundary conditions like cross-dependency of design variables Finding of correct parameter settings Support sensitivity studies e.g. for SixSigma To optimize processes or parameters or High flexibility which allows user-defined implementations Inverse calculation of parameters is possible New heat treatment module The complete heat treatment process can be simulated Heating (heating rate will influence properties) Austenizing Cooling (cooling rate will influence phase composition, stresses, and hardness) The material properties are based on the phases during the cooling phase, TTT & CCT can be be used to describe the phase transformation kinematics Austenite, Martensite, Bainite, Pearlite, Ferrite Volume change based on phase change, latent heat and plastification are taken into account Calculation of the residual stresses will be done Fast solver technology Special temperature-based step size control Inverse calculation of the heat transfer coefficient (HTC = f(temp) with the optimization module) Linking of material data and simulation results Part can be taken from forming simulation, including the plastic strain and stresses and grain size and damage (one GUI, same solver) Different heat and cooling sources can be used Local/global heating/cooling Predefined settings and heat transfer coefficients (water shower, oil bath, water bath, air..) Special Simufact.premap module Quadrilateral, hexahedral, and tetrahedral meshes are supported Structural FE simulation after heat treatment is possible Complete heat treatment cycle can be simulated in one simulation 9

10 All data depending on phases are calculated from chemical composition, given grain size and austenization temperature Flow stresses All physical properties 10