Simufact Forming 2022: Up to 4x speed-up with new parallelisation method for FV simulations

July 22, 2022

by mscsoftwareblog

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Upgrade to Simufact Forming 2022 and benefit from a new parallelisation method for finite volume simulations, improvements to cutting and damage modelling and modernisation of the GUI. Many enhancements within the new version provide more usability, efficiency and productivity to your forming process simulation.
The following top highlights are available in the new release of Simufact Forming 2022.
Faster finite volume simulations – dramatically increasing productivity at no additional cost – Hot closed die metal forming simulations using the Finite-Volume solver (First Order and Accelerated Mode) have been sped up by a factor of four allowing customers to dramatically reduce the calculation duration. These performance improvements can be used to create ever larger models and/or increase the level of detail of the simulations without compromising run times. The speed-up is achieved by a Domain Decomposition parallelisation method of the FV-Solver.
Improvements to cutting and damage modelling – Shearing and cutting processes are widely used in creating the ingots for metal forming operations and their geometry and strain-hardening of the sheard surfaces influence the subsequent forming operations. In the field of (thick) sheet metal forming processes fine-blanking steps are used to produce parts with higher geometrical complexity while reducing the number of operations which impact the forming processes in a similar way. Also, mechanical joining processes have been adopted by leading manufacturers which incorporate high-strength materials as well as cast components for BIW manufacturing. We have extended the scope of numerical optimisations of these joining techniques to these materials.
For the use with brittle or higher-strength materials we implemented damage-based separation criteria as an alternative to geometry-based separation criteria (like minimum sheet thickness) to accurately model the cracking behaviour which starts much earlier in these material groups. The new method identifies the crack path by the calculated damage gradient with the benefit of a significantly more realistic material separation. This ensures a realistic representation, for example of shearing processes as well as self-piercing riveting even with brittle or higher-strength materials.
The cuts/cracks are modelled by mesh-separation techniques in 2D models to avoid volume losses due to element deletions. In 3D models the conventional approach to use element deletion was kept for performance and stability reasons.
Modernised GUI – Our users enjoy an extensive modernisation of the Simufact Forming 2022 GUI for two reasons:
Continuous development of the GUI to achieve a modern look, better and simpler usability and UX.
Easier usability when switching between Simufact Forming and Simufact Welding by unifying the UI and UX.
Upgrade to Simufact Forming 2022 and benefit from a new parallelisation method for FV simulations, improvements to cutting and damage modelling and modernisation of the GUI. Many enhancements within the new version provide more usability, efficiency and productivity to your forming process simulation.

About Simufact Forming

Simufact Forming is an established software solution for the simulation of metal forming manufacturing processes. The software covers all essential areas of forming technology: forging, cold forming, sheet metal forming, all major incremental processes and mechanical joining. Simufact Forming provides support in microstructure simulation, calculation of die load, material flow and prediction of material properties in conventional and inductive heat treatment. Furthermore, thermo-mechanical joining methods of pressure welding are also supported.

Design and optimise your metal forming processes:

Determine the optimal amount and sequence of stages, and the process window with minimised material usage while ensuring a robust manufacturing process.

Identify & eliminate potential manufacturing errors

Optimise tool life

Simplicity – No expert knowledge required. The software solution is designed to be user-friendly, intuitive and process-oriented.
Sustainability – Save material, time and money by replacing expensive and time-consuming physical tryouts with virtual tests.
More information about Simufact Forming: https://www.simufact.com/simufactforming-forming-simulation.html