In many cases, there is a missing link in today’s product design processes. The effect of the manufacturing process is often not taken into account, resulting in inaccurate predictions of product characteristics like durability, maximum load capacity, noise, and crash resistance.

For example, a stamping process introduces varying thicknesses and residual stresses in the

parts. When stamped parts are welded together, this introduces further distortions and residual stresses in the final product. These deformations, thickness changes and residual stresses have a big impact on the strength and durability of the final product.

A solution to this problem is offered by combining the manufacturing simulation capabilities of Simufact with the CAE analysis capabilities of MSC Software.

Simufact is an OEM partner of MSC Software, and provides manufacturing simulation software and services, to customers worldwide. Simufact offers two specialized software packages:

PARTNER SHOWCASE

MSC Software: Partner Showcase - Simufact

Increased Design Robustness by includingForming and Welding Simulations

Partner Showcase: Simufact | 1

Key Highlights:

IndustryMachinery

ChallengeTo accurately predict product characteristics during the manufacturing process

MSC Software SolutionsMarc for simulating industrial forming processes

Benefits•Faster Development Process

•Tighter Integration of the Overall Design

Simufact is an MSC Software Community Partner who specializes in simulation software for the optimization and design of manufacturing processes in all areas of metal forming technology, with expertise in Marc nonlinear.

Figure 1: Integrated product design process

PARTNER SHOWCASE

2 | MSC Software

MSC Software: Partner Showcase - Simufact

Simufact.forming Simufact.forming is a simulation tool developed especially for industrial forming processes. It incorporates aspects of the previous simulation solutions, MSC SuperForm and MSC SuperForge from MSC Software. Both of those technologies were integrated into a single product capable of simulating industrial forming processes, including closed-die forging, extrusion, drawing, upsetting, bending, free forging, as well as cold, hot or warm, mechanical press, hammer or screw press operations, orbital forging and rolling processes.

Simufact.welding Simufact.welding is a simulation tool developed especially for industrial welding processes. It is based on the powerful non-linear FE technology of MSC Software, and can be used to easily model robot driven welding processes, with multiple robots and multiple weld paths per robot. An unlimited number of parts can be welded, and a flexible definition is available to model the fixture that holds these parts during the welding operation, using clamps, bearings and springs.

By integrating Simufact.forming & Simufact.welding in the overall product design process, it is now possible to have process manufacturing simulation integrated with product design. The manufacturing simulation

software allows this sophisticated technology to be used not only by CAE experts but also by product and manufacturing process designers. The process is illustrated in Figure 1.

A case study of this integrated product design process was presented at the 12th Simufact Round Table Conference, held in Bamberg-Germany, during October 2010 (http://www.

roundtable.simufact.eu/welcome.en.html).

The underlying technology that enables the connection between Simufact’s manufacturing simulation software and the CAE solutions of MSC Software is the fact that the binary output files of Simufact.forming and Simufact.welding can be used as inputs for the follow up simulations. For example, a forming simulation in Simufact.forming will create a so-called t16 file, which can be read by SimXpert, Mentat or Patran to extract both the geometry of the formed part as well as the residual stresses and strains.

The integrated product design process for a durability life assessment of a torque converter is shown in Figure 2. This figure is extracted from Reference 1, where the full presentation of this study can be found.

The durability of a torque converter is highly dependent on the residual stresses introduced during stamping of the parts, and during riveting of the parts to assemble the final product.

During the Forming process, stresses and thickness changes are introduced. These residual stresses must be taken into account during simulation of the Pressure cycling that occurs while operating the torque converter. The resulting stresses can then be entered into a calculation of the Durability assessment. The results of this process are shown in Figure 3.

In summary, the capability now exists to seamlessly integrate manufacturing process simulation, performed with Simufact.forming and Simufact.welding, into the overall product design process.

ReferencesDesign Robustness and Process Capability using 6 Sigma and Simufact.forming Dr. Kunding Wang Tagungsband 12. Roundtable “Simulation in der Massivumformung”, Bamber 2010 Page 209-220 Simufact engineering gmbh, Hamburg 2010 ISBN 978-9813814-0-5

Contact:Arjaan Bujik, Simufact-Americas LLC www.simufact-americas.com

Figure 2: Case Study for Durability Life Assessment Methodology Figure 3: Results for integrated durability life assessment

PARTNER SHOWCASE

Europe, Middle East, AfricaMSC Software GmbHAm Moosfeld 1381829 Munich, GermanyTelephone 49.89.431.98.70

Asia-PacificMSC Software Japan LTD. Shinjuku First West 8F23-7 Nishi Shinjuku1-Chome, Shinjuku-KuTokyo, Japan 160-0023Telephone 81.3.6911.1200

Asia-PacificMSC Software (S) Pte. Ltd. 100 Beach Road#16-05 Shaw Tower Singapore 189702Telephone 65.6272.0082

CorporateMSC Software Corporation2 MacArthur PlaceSanta Ana, California 92707Telephone 714.540.8900www.mscsoftware.com

The MSC Software corporate logo, MSC, and the names of the MSC Software products and services referenced herein are trademarks or registered trademarks of the MSC Software Corporation in the United States and/or other countries. All other trademarks belong to their respective owners. © 2012 MSC Software Corporation. All rights reserved.

SIMUFACT*2012SEPT*PS

About MarcAccurate, Efficient and Affordable Finite Element Analysis

Marc and Mentat combine to deliver a complete solution (pre-processing, solution, and post-processing) for implicit nonlinear FEA. Marc provides the easiest to use and most robust capabilities for contact, large strain, and multiphysics analysis available today to solve static and quasi-static nonlinear problems.

Finite element analysis (FEA) has become a critical part of the product development process, but most FEA programs are limited to solving within the limits of linear material properties and displacements, small strains, and small rotations. Many software providers claim to have nonlinear capabilities, but few are able to consistently and reliably solve problems involving changing contact conditions between components and/or large strain (plasticity or elastomeric behavior, for example). When the going gets tough, even some of the most highly regarded nonlinear-focused FEA solvers turn to explicit dynamics and

“tricks” (like mass scaling) that change the physics of problems and compromise solution accuracy. Because of these limitations, there are many aspects of product behavior that are not well understood until physical prototypes are available. This leads to late and expensive design changes, product failure in the field, and sometimes, safety issues.

Marc has no such limitations. Built from its first day to solve nonlinear problems, Marc and Mentat use advanced mathematics and FE technology to consistently obtain converged solutions for highly nonlinear problems involving nonlinear materials, large strain and displacement, and contact. Marc also incorporates serious multiphysics capabilities, enabling engineers to simulate situations involving coupling between structures, thermal, fluid, acoustics, electrical, and magnetics.

Please visitwww.mscsoftware.com

for more partner showcases

About MSC SoftwareMSC Software is the worldwide leader of multidiscipline simulation solutions that help companies improve quality, save time and reduce costs associated with designing and testing manufactured products. MSC Software works with thousands of companies worldwide to develop better products faster with simulation technology, software, and services. MSC Software is a global company with offices in 20 countries. For additional information about MSC Software’s products and services, please visit www.mscsoftware.com.