Simufact Forming

Version 2021.1
What’s New?

1 | hexagonmi.com

22. December 2021

 Simufact Forming
Version 2021.1

Introduction to VM&C
Our Product Portfolio

Costing & Estimating | Virtual Try Out | Assembly & DfAM |

Forming Feasibility Manufacturing Simulation Generative Design VM&C fields of application & Product lines
Wide range of fields of applications:
• Costing & Estimating
• Forming Feasibility
• Manufacturing & Assembly Simulation
• DfAM & Generative Design

COSTOPTIMIZER Simufact Simufact Apex Our Vision

Professional Forming Additive Generative Design
Provide smart engineering solutions
to accelerate the Industry 4.0 transformation
while improving manufacturing quality,
reducing cost and time to market.

FormingSuite Simufact Simufact

Professional Welding Joining Optimizer

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Simufact Forming 2021.1 – Top Highlights

Key improvements in Forming Limit Diagram (FLD)

Faster die load simulations

Prediction of flow defects

Extended table input for contact conductivity in RSW

Create, combine and save more detailed result animation videos

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What’s New - More highlights

• Further improvements in Tet meshing

• Import of results by range or specific increments
• Angle-based local adaptive refinement criterion
637 IMPROVEMENTS
• Compress and save newly created projects
• Histogram view of result legends Documentation
Features
23%
10%
• New meshing and remeshing defaults
• Newly redesigned icons

Bugs fixed
28%

and more … Others

39%

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 Simufact Forming
Version 2021.1

Key improvements in Forming

Limit Diagram (FLD)

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 Simufact Forming
Version 2021.1

Forming limit Diagram

Three methods introduced to define FLD curve

• Abspoel and Scholting (Recommended)

• Suitable for all steel types including AHSS
• Material parameters
• Inputs from Tension test
• Total elongation, r-value and sheet thickness

• Keeler
• Suitable for Mild and conventional steels
• Material parameters
• Inputs required from Tension test
• Strain hardening exponent (n value), sheet thickness

• Tabular
• Direct import (csv) of experimentally measured FLD data
• Support for both Engineering and True strain options

Accurate prediction of formability by simply defined but accurate empirical models with
no experimental effort
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Version 2021.1

Forming Limit Diagram

Predictive models

Predictive method also works for

aluminum, stainless steel and
next generation steels.

Recommended for all steels

Conventional steels
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Version 2021.1

Forming Limit Diagram

Wrinkling prediction

Source: Numisheet 2018 BM2

Spot the safe, thinning and wrinkling areas effectively

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 Simufact Forming
Version 2021.1

Forming Limit Diagram

Failure prediction with Abspoel and Scholting model

Source: Numisheet 2018 BM2

Accurate fracture prediction without time-consuming Nakajima or Marciniak

experimental testing
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Forming limit Diagram
Uses all strain(in and out of plane) points in the simulation

• The major and minor strains vary along the thickness and often this information is neglected when thin shell elements
are used in a simulation, and only middle layer strain information is shown in the FLD plot.
• The below picture shows the importance of considering all strain points in the simulation using solid shell elements, and
all points are plotted in the FLD plot.

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Forming limit Diagram
Further improvements

• Major strain and Minor strain are calculated only from plastic strain fraction

• Major, Minor and Thickness strain can be evaluated as engineering and true strain

• Forming limit diagram can be displayed as engineering strains or true strains

• Damage models and forming limit diagram can be used in one simulation simultaneously

• Initial sheet thickness from workpiece is automatically used to adjust Abspoel & Scholting and Keeler material models
(no need to create a new material when initial sheet thickness from workpiece is changed)

• Strain points can be selected in the forming limit diagram (multiple selection by the Ctrl key) and points are highlighted
in the transparent workpiece

• Forming limit diagram can only be activated in the sheet metal forming application module and not in 2D analyses

• Engineering thickness strain is calculated with following formula:

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 Simufact Forming
Version 2021.1

Faster sheet forming

simulations

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 Simufact Forming
Version 2021.1

Faster sheet forming simulations

• Sheet metal forming processes with Solid shells

elements by a factor of 2 faster in SIM 2021.1
compared to previous version

• Improved and suitable default values during the

simulation

~2x Speed up in wall time

Manufacturing of a b-pillar sheet

(Automotive)

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 Simufact Forming
Version 2021.1

Faster sheet forming simulations

How much faster do sheet metal forming simulations run with contact separations reduced to 10, ideally without compromising
result quality?

• Based on some studies, one can start with 10 separations. But if the user observes bad convergence (→ convergence monitor), then this
value must be changed back to the default 99.

• In addition, Segment to Segment (S2S) contact saves significant time in most cases.

Hex, separations S2S contact N2S contact Separation Stress (MPa)

Hex, 5 2818s 4997s 10
Hex, 99 2723s 9590s 10

• If S2S contact is preferred, the currently used convergence option ‘residual OR displacement’ may not produce optimum results
for every problem. It must be modified to ‘residual AND displacement’ to make sure that the force residuals are within the allowed
tolerance limit.
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 Simufact Forming
Version 2021.1

Faster die load simulations

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 Simufact Forming
Version 2021.1

Faster die load simulations

Improved element set definition

• From our tests, V2021.1 shows a maximum of 8x

speed up in die load simulations compared to V2021. 2021 2021.1
Samples Time saving
Wall time in s #Increments #Elements Wall time in s #Increments #Elements

A 8023.17 13 94076 1045.04 13 94076 86.97%

B 5.17 2 4820 4.55 2 4820 11.99%
C 274.29 10 30621 105.48 10 30621 61.54%

~8x Max. speed up in wall time

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 Simufact Forming
Version 2021.1

Prediction of flow defects

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Version 2021.1

Prediction of flow defects

Piping effects

• Piping effect is very difficult to be detected from simulation

results. Post particles must be defined for this at the right
place and at the right direction.

• A new post value called ‘Flow defects’ shows areas with high
or low risk of defective material flow.

Identify flow defects at a

glance

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 Simufact Forming
Version 2021.1

Improvements in
fold detection
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 Simufact Forming
Version 2021.1

Improvements in fold detection

• No calculation time loss when using the fold

detection in a DDM simulation

• Intuitive definition of the distance between

workpiece surface and fold mesh in forming control

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 Simufact Forming
Version 2021.1

Tet meshing improvements

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 Simufact Forming
Version 2021.1

Tet meshing improvements

• Checking of the Tet volume mesh after remeshing, whether generated elements meet defined quality criteria

• Automatic meshing strategy implemented to improve volume mesh quality

• Splitting and smoothing of Tet elements on the surface, if quality (user-defined) criterion is not reached

Input Output

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Robust Tet meshing

 Simufact Forming
Version 2021.1

Tet meshing improvements

• Automatic meshing strategy implemented to improve volume mesh quality

• Removing of very flat Tet elements only at the workpiece surface, if quality criterion not reached

Input Output

23 | hexagonmi.com Robust Tet meshing

 Simufact Forming
Version 2021.1

Tet meshing improvements

• Automatic meshing strategy implemented to improve volume mesh quality

• Testing with an angle-based quality criterion for areas with critical sharp angles prior to volume meshing

Input Output

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 Simufact Forming
Version 2021.1

New meshing and remeshing

defaults

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 Simufact Forming
Version 2021.1

New meshing and remeshing defaults Standard

• New default values in meshing and remeshing settings for FE and FV models:

• FE: Minimum element size: 1/5 → 1/3; Coarsening factor: 1.5→1.3; Curvature divisions: 10→7

• FV: Minimum element size: 1/5 → 1/4; Curvature divisions: 12→10

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Lesser elements, faster simulation
 Simufact Forming
Version 2021.1

Extended table input for

contact conductivity
Resistance Spot Welding (RSW)

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 Simufact Forming
Version 2021.1

Extended table input for contact conductivity in RSW

Based on two independent variables

• Contact conductivity plays a vital role in

generating heat between different contacts in
resistance spot welding processes.

• The earlier versions allowed only a table input of

conductivity dependent on temperature but not
normal stress.

• V2021 has a new option Table z(x.y) where a

table can be added or imported to define contact
conductivity values dependent on two
independent variables namely temperature and
normal stress/pressure.
Extended electrical properties depending on
Normal stress and Temperature
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 Simufact Forming
Version 2021.1

Create, combine and save

more detailed result animation
videos
• Append multiple result animations to
create a single video
• Save animation along with History plot
as *.avi file

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Version 2021.1

Append multiple result animations to a single video

Generate one video from several result views

• It is now possible to create one single

videos from multiple result views by
appending each animation one after
the other.
• Users can manually add new
animations by clicking on the result
views with the button to combine
new animations to one video.
• This feature is highly beneficial for
processes having multiple stages.
• The Timeline pane displays the order
of the different animations which can
One animation video for
be rearranged as desired using the multiple processes or stages
arrow buttons.
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 Simufact Forming
Version 2021.1

Save animation along with History plot as *.avi file

See THS plot in the result view

• Export and save animation with the Time-History Plot (THS) by pulling it to the main result view.

• By clicking on Open plot in View button in the History plot window. the THS plot can be transfered to the result view and
back as desired.

• The result view can be then recorded and saved as a video (*.avi format) with the THS plot .

More details in a
single video

Save animation

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 Simufact Forming
Version 2021.1

Import of results by range or

specific increments

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 Simufact Forming
Version 2021.1

Import of results by range or specific increments

With selection assistant or wizard

• Import results option is improved further to

importing a user-specific range of increments
necessary for post-processsing.

• This significantly reduces the time needed to read

and import results from large models having a
huge result folder size.

• By limiting the increments to necessity, the time

delay of importing results from remote machines
which depends on the network connection can be
easily avoided.

• The Selection assistant helps manage the result Import results to

increments as per user needs. user preference

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 Simufact Forming
Version 2021.1

Angle-based local adaptive

refinement criterion

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 Simufact Forming
Version 2021.1

Angle-based local adaptive refinement criterion

For solid-shell elements

• A new local adaptive refinement criterion

named Angle between elements is introduced
based on angles.

• This refinement is dependent on the allowed

change in angle between neighbouring shell
elements during simulation.

• If the angle change in the mesh becomes

greater than the Trigger value the element
refines further.

The lower the triggering angle –

the more elements created

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 Simufact Forming
Version 2021.1

Compress and save newly

created projects

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 Simufact Forming
Version 2021.1

Compress and save newly created projects

• The Save as option for creating and saving a new project

includes a new checkbox named Compression.

• When activated, the project will be compressed and saved in

the desired folder by calling tar.exe available in Windows 10.

• The new saved project is only created but not opened in the
GUI. A compression algorithm creates an archive out of this
newly created project.

Compress new projects

while saving

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 Simufact Forming
Version 2021.1

Histogram view of result

legends

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 Simufact Forming
Version 2021.1

Histogram view of result legends

Continuous

• Users can enable/disable the Histogram

view of the result legend by the context
menu.

• It helps users to identify how often a

certain result value range persists through
time based on nodes. surface area or Discrete

volume.

• It can be displayed either in continuous or

discrete mode

Legend in Histogram
view
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 Simufact Forming
Version 2021.1

Plot max./min. values of user-

defined results in history plot

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 Simufact Forming
Version 2021.1

Plot max./min. values of user-defined results in history plot

• Users can now generate history plots from max./min. values from a user defined result values and view them.

• The following figure shows an example of an user defined result value ‚Test‘ and a plot with the minimum nodal values of
this result named ‚TestMIN‘.

Extended user-defined THS plots

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 Simufact Forming
Version 2021.1

Mapping using Digimat-MAP

Compatible with ARC result files

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 Simufact Forming
Version 2021.1

Result mapping using Digimat

• Digimat-MAP 2021.4 now reads Simufact ARC files and generates output for 3rd party products enabling data exchange
between Simufact.

• Digimat currently maps only stresses. Other result values will be added in future releases of Digimat-MAP.

Map stresses using our ARC files

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 Simufact Forming
Version 2021.1

Redesigned icons

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 Simufact Forming
Version 2021.1

Newly redesigned icons

Modernised GUI
2021 2021.1
• Some important icons used in the older versions
are redesigned and updated for a better
aesthetics and experience.

• Some examples of the new icons are shown here.

Better icons for better aesthetics

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 Simufact Forming
Version 2021.1

Other improvements

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 Simufact Forming
Version 2021.1

Other improvements
• Improved disk space management by reducing result file size (~50%) leading to a speed-up during first reading and
visualisation of results.

• Default values are displayed as automatic in contact table for better representation.

• Hide objects i.e. geometries from main view when contact table is open.

• Unified selection behaviour of context menu in view with process tree selection for better usability. (Multiple selection of
components in the model and result window by pressing the CTRL key)
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 Simufact Forming
Version 2021.1

Other improvements
• Added *.t19 output choice to additional result files.

• Automatic synchronisation of simulation progress when several result windows (i.e. THS plot. result view) of a process are
open.

• Improved camera settings menu in the main view.

• Display of min./max. result values adjusts to the shown range when general filter is used to filter out certain elements or
nodes.

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 Simufact Forming
Version 2021.1

Other improvements
• Input and use of user-defined translation vectors for positioning under manual positioning.

• User-defined unit system is overwritten when switched to a predefined unit system when editing.

• Orange highlighted transformation vector displayed during translational or gravity based positioning.

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 Simufact Forming
Version 2021.1

Other improvements
• Improved vector filtering with possibility to switch between two display modes:
• Averaged vectors
• Original maximum/ minimum vectors

• Redesigned Temperatures setting dialog for dies and workpieces. Automatic HTC additionally supports a cut-off value
called Lowest allowed HTC value below which the auto-calculated HTC value is disregarded.

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 Simufact Forming
Version 2021.1

Other improvements
• Lock the user-defined aspect ratio for taking a screenshot or a video.

• Added ksi (kilo-psi) to stress in the unit system.

• Default value for efficiency factor in resistance welding process is set to 1.0.

• Updated CAD import to use latest CADFix release 12/SP2 libraries.

• Modified convergence settings for solid shell element for all sub-stages as residual=0.1.

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 Simufact Forming
Version 2021.1

Other improvements
• Added Segment-to-Segment support for die wear calculation with DDM.

• Improved selection of points on clipping plane using Query tool.

• New Shortest path selection mode where the user can specify the distance
between the selected nodes along the path and to search for a path along the
edges of the mesh.
• Default distance for path selection is 5mm.

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 Simufact Forming
Version 2021.1

Improvements in Sf Material

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 Simufact Forming
Version 2021.1

Improvements in Sf Material
Select multiple areas of application for easy material filtering

• Multiple selection of area of application is now possible

for material filtering.

• User can check the desired areas of application to look

for an applicable material.

• Simufact Material. called from Forming GUI the first time.

pre-selects the area of application based on the forming
processes.

• Last user-defined selection is saved and applied when

the library is called the next time.

Filter materials suiting more than one

area of application
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 Simufact Forming
Version 2021.1

Improvements in Sf Material
• Extended Linear austenitization definition dialog:
• Austenitization definition per phase pair possible.
• Separate definition of Latent heat, Transformation strains and TRIP for each phase pair.

• Added input of Martensite finish temperature (Mf) for Koistinen-Marburger parameters (Leblond based) above which no
martensite formation happens.

• Improved import/export of flow curves for easier creation. viewing and editing using peak temperature dependencies.

• Sf Material supports Creep data from JMatPro using Table.

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 Simufact Forming
Version 2021.1

Removed features & default

settings changed

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 Simufact Forming
Version 2021.1

Removed features

• Removed electrical-thermal conversion factor from Sf Material and introduced ‘Process efficiency factor’ in Sf Forming.

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 Simufact Forming
Version 2021.1
Standard
Overview of new standards and defaults
NEW OLD
Convergence criterion if Solid-Shell elements used - Convergence criterion if Solid-Shell elements used -
Residual: 0,1 Residual: 0,01
Convergence criteria for release load cases in sheet metal Convergence criteria for release load cases in sheet metal
forming are checked for „Residuals and displacements“ forming are checked for „Residuals or displacements“
Fold mesh has a constant distance to the surface of the Fold mesh has a variable distance to the surface of the work
work piece (distance: 0,2 mm) piece (depending on the element size / FV element size)
If process tree is selected or the THS plot opened by the If process tree is selected or the THS plot opened by the
user: All tools are selected if a press is defined user: All tools are not selected if a press is defined
Process efficiency is set to 1 (= 100%) for pressure welding Process efficiency is set to 0,5 (= 50%) for pressure welding
processes processes
Major and minor strains are calculated using the plastic Major and minor strains are calculated using the plastic and
deformation only elastic deformation components.
Default meshing parameter for Tetraeder/Trias adjusted

Automatic calculation of base edge length for Tetraeder was

adjusted

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 Where Simulation Gets Real

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