[Case Study] Predicting Defects in Press Forming and Sheet Forging Using CAE Applications

The advanced feature of the CAE software "DEFORM," known as "strongly coupled analysis," is a method that allows multiple physical phenomena to interfere in real-time. However, in practice, the key consideration is whether the accuracy gained justifies the increase in computation time. In this article, we conducted a comparative verification of strongly coupled and weakly coupled analyses using the forging of helical gears as a subject. We visualized the differences in analysis results from three perspectives: "load," "contact pressure," and "stress." For more details, please refer to the related links.

In optimizing the heat treatment process, it is impossible to separate the flow of gas from the changes in the quality of the workpiece. The CAE software "DEFORM" allows for seamless coupling of fluid analysis (CFD) and gas quenching analysis within the same software. [Key Points of This Case] - Visualization of Gas Behavior: Precisely understanding the velocity distribution and flow bias within the cooling tank. - Prediction of Quenching Quality: Analyzing the temperature and microstructural changes of each part of the helical gear over time according to the flow. - Identification of Cooling Irregularities: Quantifying the heat transfer rates for specific areas such as the tooth tip, tooth root, and inner diameter. DEFORM's unique strength in simulating "from fluid to quenching" in a continuous manner supports next-generation quality design. For more details, please refer to the related links.

In press die design, the settings for "pilot hole diameter" and "vertical wall height" in burring processes tend to rely on empirical rules and trial-and-error. This is particularly true for high-strength steel sheets (high-tensile), where the risks of cracking and thickness reduction are significant, requiring a considerable amount of time to establish conditions. The plastic processing simulation software "DEFORM" addresses these challenges. 【Identify the "correct answer" with CAE before actual prototyping】 By utilizing DEFORM's "Design of Experiments (DOE)" feature, multiple conditions such as pilot hole diameter and punch shape can be digitally verified all at once for formability. This allows for a quantitative understanding of forming limits and cracking risks, enabling the derivation of optimal processing conditions in a short time. For more details, please refer to the related link.

Are you struggling with the phenomenon where holes, which should ideally be "perfectly round," become distorted in the manufacturing of automotive motor cores and electronic components? Even if we can speculate that mold deflection is the cause, measuring the behavior during processing is difficult. As a result, the current situation often involves repeatedly prototyping based on "intuition and experience," leading to enormous time and cost spent on corrections. In this case study, we used the plastic processing simulation software "DEFORM" to reproduce the phenomenon of hole ovalization. We clarified the mechanisms of distortion that had previously been a black box. - Identifying factors: Quantifying the impact of mold and machine rigidity on precision. - Pre-validation: Simulating the effects of countermeasures before prototyping to reduce rework. For more details, please refer to the related links.