Our Manufacturing Simulation Services Includes

• Sheet Metal Forming
  • Hydro forming
  • Tailor Welded Blanks
• Powder Metallurgy
• Casting Simulation
• Heat Treatment
• Welding
• Forging
• Rolling

Sheet Metal Forming

• Stamping / Deep drawing
• Hydro forming ( Tube and Sheet)
• Tailor welded blank
• Stretch forming
• Spring back estimation
• Prediction of thinning /stretching
• Tool and die design verification
• Formability verification
• Prediction of wrinkles and folds

Hydro forming

Tailor Welded Blanks

Powder Metallurgy

P/M Components & Processes; Design & Optimization

• Compaction simulation
• Densification prediction
• Spring back estimation,
• Sintering simulation
• Shrinkage & distortion
• Prediction, tool stress and
• Deflection estimation
• Tooling/process design
• Optimization

Casting

• Sand (Grey, Ductile, Steel, Al ) / Investment casting
• Gravity / High Pressure die casting
• Permanent mold / Shell Casting
• Develop die / gating design and process plan
• Verify the Tool design by FEM simulation and analysis
• Reducing rejections due to porosity formation, cold shuts.
• Yield improvement.
• Optimization of riser

Heat treatment

• Residual stress prediction
• Distortion prediction
• Distribution of metallurgical phases (Austenite, bainite, ferrite, martensite etc)
• Grain size and Hardness distribution
• Location of cracks.
• Tool failure analysis

Welding Simulation

Our expertise includes

• Residual stress
• Distortion
• Heat Affected Zone (HAZ)
• Fatigue, fracture and durability of welded structures
  TIG/ MIG/ LASER/ELECTRIC ARC/ ELECTRON BEAM/ ELECTRICAL SPOT RESISTANCE welding (single/ multi pass) are simulated using FEM tools.

The Process Model can be used for

• Weld sequence optimization
• Complete understanding of the welded component during welding, cooling and in service

Forging

• Develop die design and process plan
• Verify the die / tool design by FEM simulation and analysis
• Modify tool design for new materials.
• Yield improvement / flash reduction, reducing rejections
• Reducing number of stages, cycle time
• Optimize the metal flow
• Optimize the power / press tonnage
• Predict stress, strain, strain rate, stresses, temperature in work piece and dies.
• Predict defects laps / folds/ underfils
• Die stress analysis

Rolling

• Shape rolling, profile rolling.
• Sheet rolling, HSM modeling,
• Offline simulator to predict microstructure in rolling.
• Heat transfer modeling of the ROT, down coiler.
• Predicting of camber angle.