Tutorial

Simufact Forming
Introduction to Simufact Forming 2021

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Introduction to Simufact Forming 1
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Table of contents
Simufact Forming basics tutorial
Throughout this
◆ This tutorial is intended for first time users of Simufact Forming. It will tutorial a lot of
explain the basic concepts of the software and show you its capabilities helpful tips and
as well as demonstrate the typical workflows. tricks will be shown
in this sidebar. The
◆ The topics covered in this tutorial are: categories are:

◆ Simulation basics Note: helpful

◆ Introducing Simufact Forming information for
starters
◆ Preprocessing Tip: hints and
background
◆ Calculation information
◆ Postprocessing Important:
essential information
◆ Advanced modeling techniques Warning: risk of
data loss or
◆ Troubleshooting malfunctions
◆ Simulation quality Caution:
possible sources of
◆ User customization errors

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Infosheet
Tutorial chapter
Demo example

Introduction to Simufact Forming 3

 Basics tutorial

Simulation basics

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back to p.1
Introduction to Simufact Forming 4
Simulation basics
What is manufacturing simulation?
Simulation …
“Simulation reproduces a system with its dynamic processes, within an experimental
model, to gain knowledge, that is transferable to reality.” …is an aid for
process and tool
External design.
Analysing the effects
Real process, collecting
…shows what is
process the system possible and what is
properties and not.
external effects
System
properties …supports the
forming expert but
Source: ZF Friedrichshafen AG cannot replace him.
Validation Interpretation
…enables a
deeper process
understanding.

Results Solver Const.

…saves time
consistent with

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and costs for
reality? experiments on the
Homogeneous
machine.

Introduction to Simufact Forming 5

Simulation basics
Simufact product lines

Simulating Manufacturing - The Manufacturing Division of Hamburg

Simufact offers
over 25 years of
experience in the
field of simulating
manufacturing
processes. More
than 100 experts
attend to over 1000
satisfied customers
worldwide.
Fraunhofer IWU

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Supporting the optimization of metal-based manufacturing
processes

Introduction to Simufact Forming 6

Simulation basics
Simufact Forming applications
Classical forming applications:
METAL FORMING

You can simulate

Cold Hot Sheet metal Rolling Ring Open die nearly every
forming forging forming rolling forging possible metal
forming process with
Simufact Forming.
All metal forming Additional complementary process types: From simple
upsetting tests to
applications, complex open die
independent from forging kinematics.
temperature,
Simufact
material, Pressure Mechanical Heat General Forming is being
machine, and its welding joining treatment constantly updated.
New versions will
kinematics. likely cover new
areas of application!

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Introduction to Simufact Forming 7
Simulation basics
Structure of Simufact Forming

These are the

three main modules
that are necessary
for every simulation.
Post processor Simufact Forming
Pre processor Solver combines all of them
(Result validation and
(modeling) (calculating) into one program.
interpretation)

Graphical User
• CAD import • Assembly of K • Result display Interfaces allow a
−1
• Element selection • Solving of u = K F • Deformed structure user-friendly model
• Material definition • Strain • Stress distribution setup (pre
• Initial conditions • Stress • Temperature distribution processing) and
• Boundary conditions • Force analysis evaluation
• Force application • Total equivalent plastic (post processing).
• Kinematic strain
•…

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Introduction to Simufact Forming 8
Simulation basics
The core of manufacturing simulation: The material
◆ The key item of every forming process is Simufact
Material currently
the workpiece. contains over 700 of
◆ Its inherent properties (mechanical, the most commonly
used materials!
thermal, electrical,…) are defined by the
associated material data.
Users can add
◆ Especially the mechanical material new materials and
properties can be quite complex and are expand the library
with their own data.
a source of non-linearity which results in For more detailed
significant computational efforts. information about
this please see the
◆ Simufact Forming comes with its own Simufact Material
extensive material library, Simufact manual!
Material. Nearly all included materials
use elastic-plastic material models. For even more
advanced
→ respects elastic deformation applications special
→ respects strain rate dependencies models to predict
→ respects plastic deformation grain size evolutions
and phase

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(including hardening and softening) transformations are
available.
Conventional and true stress-strain
diagrams for ductile material (steel)
Source: R.C.Hibbler-Mechanics of Materials

Introduction to Simufact Forming 9

 Basics tutorial

Introducing Simufact Forming

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back to p.1
Introduction to Simufact Forming 10
Introducing Simufact Forming
Solver technology: Finite Elements (FE)
Hexahedron
◆ The Finite Element Method divides the part elements deliver the
geometry into a finite best result quality
number of elements (discretization). with respect to
stresses, strains and
◆ Simufact forming provides quad elements damage.
for 2D simulations
and tetrahedron or hexahedron elements Simufact
Forming comes with
for 3D simulations. multiple meshers to
◆ Hexahedron elements are always the first create finite element
choice if accurate results meshes for your
workpiece without
are required. the need for third
◆ The finite element method is based on the party meshing
implicit MSC.Marc solver. This
8 programs.

non-linear finite element solver is highly

productive, multifunctional and offers
5 During the
forming process the
effective parallelization options.
7 finite elements get

◆ The FE solver is the standard solver for 6 4 distorted. Simufact

Forming can

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most forming simulations. perform automatic
1 remeshings for an
3 optimal
quality.
result

2
Introduction to Simufact Forming 11
Introducing Simufact Forming
Solver technology: Finite Volumes (FV) Only the surface
of the workpiece is
◆ The FV solver is based on the explicit discretized via a
MSC.Dytran solver and originates from the surface trias mesh
computational fluid dynamics (CFD) simulation. and the material
moves through a
◆ Its strong suit is predicting material flow. stationary grid of FV
◆ The FV solver in Simufact Forming is elements.
specifically designed for hot forging
applications. It is not recommended for other For suitable
process types. processes the FV
solver is around 4 –
◆ The characteristics of hot forging processes fit
10 times faster than
the requirements of the FV solver: the FE solver with
▪ High temperatures → low flow stresses, comparable result
easy material flow qualities.
▪ High strain rates → dynamic material
movement, short process times The FV solver is
very stable in self
▪ Constrained material movement through contact situations
forging dies → only little free movement such as fold
◆ Classical applications are hot closed die formations.
forging operations or hot extrusion processes.

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◆ FV simulations can show small details such as Do NOT use the
folds and flash formings, because a fine FV solver for
surface discretization is not as costly as an processes that do
not meet the
equally fine finite element mesh would be. requirements for FV
simulations!

Introduction to Simufact Forming 12

Introducing Simufact Forming
Application modules and process types
◆ Simufact Forming offers
Choosing an
many application modules application module
tailored to the needs of is the first step you
various forming processes. will do when
creating a new
◆ Every application module process simulation.
contains individual default
settings for solver, mesher The brief
description will help
and different process types you choose a
(e.g. upsetting, extrusion, suitable application
heating, etc.). Click for more module for your
information in simulation.
◆ This helps the user to
achieve good simulation the infosheet!
Watch out for
results without having to the infosheet icon.
Many dialogs offer
delve into the more detailed information
advanced settings. at the click of this
◆ Some application modules button.

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contain exclusive machine
kinematics (e.g. ring rolling,
open die forging).

Introduction to Simufact Forming 13

Introducing Simufact Forming
Simulation type: 2D or 3D simulation, process chain 2D simulations
are strongly
◆ Full 3D calculation is meant for complex workpiece geometries. Symmetry recommended when
planes (segments) or the cyclic symmetry option can save valuable computation the simplification is
time. acceptable!
◆ 2D axisymmetric simulations can often be used for upsetting or extrusion
processes. 2D simulations
◆ 2D planar simulations are suitable for many rolling operations. in Simufact Forming
are set up with 3D
◆ Simufact Forming fully supports result transfers from 2D to 3D simulations. You geometries which
can set up the preforming operations of a multi stage process as 2D simulations will be cut at a later
and expand into 3D around the rotation axis as soon as it is required by the stage. So there is no
shape of the workpiece. This expansion is also possible for 3D symmetrical need to generate
processes. special 2D
geometries inside
◆ This enables a quick and easy setup of whole process chains! your CAD system!

2D simulations
can save a lot of
computation time as
the element count is
typically lower.

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The shown ring
rolling process chain
can be found in the
Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Demos&Examples
Upsetting Upsetting Trimming Cooling Ring Rolling explorer!
(2D) (2D) (2D) (3D) (3D)

Introduction to Simufact Forming 14

Introducing Simufact Forming
The Simufact Forming GUI:
1 Getting used to
2
YOUR LOGO YOUR LOGO
the Forming
HERE! HERE! vocabulary will help
with future learning!

5 6 The GUI is
designed to be
modular. You can
hide/display or
rearrange most
3 4 elements!

Hovering your
mouse pointer over
a button in the
toolbars will display
a short hint about its
functionality!

You can add the

logo of you
2 company! See

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Extras > Options >
Settings > Graphics.
1: Menu bar 2: Toolbars 3: Process tree
4: Object catalog 5: Model view 6: Result view

Introduction to Simufact Forming 15

Introducing Simufact Forming
Process tree and object catalog:
◆ Simufact Forming is based around working Note the
difference between
with objects. an object and a
◆ Objects can be almost anything from component!
geometries to materials, to physical properties
The press object
or mesh information. is an exception as it
◆ The object catalog collects and contains every is directly assigned
object that you have used in your project. to the process and
can contain
Process Object ◆ To create a simulation you fill the process tree components.
tree catalog with objects.
Expand or
◆ Use drag and drop to move objects from the collapse the
object catalog to a component in the process contents of a
tree. process or single
components with the
◆ The same object can be simultaneously used + and – buttons!
in multiple processes.
◆ A component acts like a container that can You can use
filter functions for
contain multiple objects.

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both process tree
◆ The process tree contains additional items that and object catalog to
keep big projects
are neither component nor object like the clearly.
ambient temperature and the forming control.

Introduction to Simufact Forming 16

Introducing Simufact Forming
Components and Objects:
◆ Typical components in a Simufact Forming simulation are the dies and the The icon of the
workpiece. die component
changes depending
◆ You can add numerous dies to a process but only a single workpiece can on the selected type!
be present (note the ).
◆ There are different types of dies e.g.: A deformable die
▪ Rigid dies without heat conduction can act as a second
▪ Rigid dies with heat conduction workpiece!

▪ Deformable dies
Not every object
◆ Objects are assigned to components. can be assigned to
◆ Every object contains specific information that is used to define the multiple components
component. (e.g. geometries)!
◆ Some objects are mandatory, some are optional or situational.
Dies need at
component least a geometry, a
friction and a
object temperature object!

Rigid dies without heat The workpiece

conduction still respect heat needs at least a

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transfer between bodies. mesh, a geometry, a
material and a
Only the distribution of heat temperature object!
inside the die is idealized and
stays constant.

Introduction to Simufact Forming 17

Introducing Simufact Forming
View manipulation and interacting with Simufact Forming:
◆ Mouse controls:
Left mouse button (LMB) Right mouse button (RMB) Middle mouse button (MMB)

If your system is
set up for a left
handed mouse,
Single click = select Single click = context menu Scroll wheel = zoom in / out Simufact Forming
will adapt
Hold = pan view / drag Hold = rotate view Hold + drag = zoom box
accordingly!
Double click = reset zoom
In addition to a
◆ Keyboard controls: regular mouse, the
use of 3DConnexion
➢ Please refer to the infosheet for all available keyboard shortcuts: space navigators is
supported as well!

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© 3DConnexion

Introduction to Simufact Forming 18

Introducing Simufact Forming
Unit systems in Simufact Forming:
◆ Unit definitions in Simufact Forming are completely flexible.
◆ You can select and work with the units for your in- and output values that Flexible GUI
driven unit
you desire. conversion makes
◆ Simufact Forming maintains a consistent unit system in the background so working on projects
with international
that you don’t have to convert it manually. colleagues much
◆ The GUI can do live unit conversions for you. easier!
◆ You can adapt the default units for all values to your liking.
You can change
the default unit
settings via the
menu bar under
Extras > Options >
Units.

Hold the Ctrl key

on your keyboard
while selecting a
different unit to
suppress the

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automatic
conversion.

Introduction to Simufact Forming 19

Introducing Simufact Forming
Simufact Forming help and documentation system:
◆ Simufact Forming aims to provide you with the required information where
you need it. Every piece of
information available
◆ Keep an eye out for brief descriptions, linked infosheets , tutorial about Simufact
chapters or demo models ! Forming is
accessible via the
◆ Simufact maintains a vast array of example processes which are available Help menu:
for every user.
◆ For many of these demos detailed descriptions and step-by-step model
setups are provided in the application tutorial.
◆ These demos & examples will help you set up similar processes with ease.

Infosheets are
spread throughout
the Simufact
Forming GUI and

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provide valuable
information!

Introduction to Simufact Forming 20

Introducing Simufact Forming
Setting up your first simulation with Simufact Forming
◆ We have created a video tutorial where the complete set up of a simple There will be
upsetting process is shown and explained step by step. more detailed video
tutorials like this one
◆ If you are a first time user of our software you should take the time and in future versions of
follow the video instructions to set up this model by yourself to get Simufact Forming!

acquainted with the look and feel of Simufact Forming.

The completely
set up model is
available in the
Demos&Examples
browser under
Tutorial > Cold
forming > Upsetting
of a cylinder.

You can find

similarly detailed
step by step
descriptions in the
application tutorial or
directly linked in the
Demos&Examples

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Click the play browser for every
model in the tutorial
button to play the category.
video!

Introduction to Simufact Forming 21

 Basics tutorial

Preprocessing

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back to p.1
Introduction to Simufact Forming 22
Preprocessing
What is preprocessing? During
preprocessing, the
◆ During preprocessing you set up the model of model view is
your process so that it contains all the automatically
information that is needed for a successful updated when you
simulation. assign new
geometry objects to
◆ For a basic forming model, the main steps are: the workpiece or die
▪ Select a suitable application module and components!
process type.
▪ Import (and position) geometries. When adding
objects to the object
▪ Choose the desired material. catalog, for standard
▪ Define a press (machine motion). forming processes,
you can go through
▪ Specify friction properties. the first 5 entries of
▪ Specify heat properties. the context menu
and you should have
▪ Create a workpiece mesh. all the objects you
▪ Possibly adapt some simulation settings. need!
▪ Start the simulation!
You can create
process templates to

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◆ Except the first, all these preprocessing concepts increase your
of Simufact Forming will be described in this efficiency when
working repeatedly
chapter. Application modules and process types with similar
have been covered previously. processes!

Introduction to Simufact Forming 23

Preprocessing
Difference between analytical and discrete geometries

Internally,
Simufact Forming
only uses discrete
geometry
Discretization descriptions!

Analytical
geometries must be
discretized!

A discrete
◆ Analytical description ◆ Discrete description description is always
an approximation to
▪ Description via ▪ Description via the real geometry!
mathematical functions discrete surface facets
(e.g. NURBS splines or Discretization
▪ Approximation of can be done during
faces) curved facets → the export of the
CAD system or
▪ Ideal geometry depiction discretization error during the import

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▪ File formats: IGS, STEP, ▪ File format: STL into
Forming.
Simufact

CATPart, etc.

Introduction to Simufact Forming 24

Preprocessing
Importing analytical geometries: CAD import/preview You can import
complete
assemblies as well.
◆ Open the CAD import dialog via Geometry
> CAD import. Pros and Cons
◆ You can control the discretization options in of CAD import with
Quality facets:
the next dialog.
+ More stable
◆ There are two import parameters: contact calculation
(especially in FV
▪ Quality facets simulations!)
▪ Facet sag + Enables the use
◆ Quality facets: of the „mesh on
STL“ function (see
▪ Activate to enforce the creation of meshing)
equilateral triangular surface facets. + Improves the
▪ Recommended for most simulations. result quality for
results that are
◆ Facet sag: calculated on the die
▪ Controls the discretization error. surface (Wear) or
mapped on the die
Uncheck the box to enter a value surface (contact
manually (in mm). pressure)

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- Much higher facet
count (→ increased
calculation time)
- Not recommended
for 2D simulations.

Introduction to Simufact Forming 25

Preprocessing
Importing and remeshing discrete geometries (STL) Depending
your CAD system
on

the names of the

◆ Open the STL import dialog via Geometry > parts might or might
From file. not be saved in the
STL file. If it is not,
◆ Do not import discrete geometries (STL files) the default name will
via the CAD import function! be generated from
the file name.
◆ STL files generally do not contain much
information besides the coordinates of the
This is also true
surface facets. for complete
→ You have to select the correct dimensions assemblies saved in
(Default = mm) one STL file.

When using the

◆ If you are not satisfied with the imported Surface remesh
option you can set a
surface facets you can remesh it. high element size
◆ To do so right-click the geometry object and and a smaller
minimum size
select Modify geometry > Surface remesh. (<1/5th) in the
◆ Keep in mind that a remeshing cannot advanced
improve the actual geometry representation. parameters. This

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way you can
achieve an
increased spreading
from small to big
facets to reduce the
total number.

Introduction to Simufact Forming 26

Preprocessing
Creating simple geometries: Basic shapes Basic shape
geometries are often
◆ Typically, workpiece and especially tool used as workpiece
geometries are created in the users‘ CAD geometries. You can
easily create blocks,
system of choice and then imported to billets, pipes or
Simufact Forming. sheets of different
sizes.
◆ However, it is possible to create simple
geometries directly in Simufact Forming Basic shape
without having to use any CAD software. dimensions can be
edited. Edit function
◆ The available shapes are: can be found in
▪ Cube Modify geometry
submenu. Basic
▪ Cylinder or section of desired angle shape edit creates a
▪ Hollow cylinder or section of desired copy.

angle
Cubic
▪ Rounded cube autoshapes tend to
have very few but
◆ You can add these shapes to the object very big surface
catalog by selecting Geometry > Basic facets. If you want
shape in the context menu. them to have a finer

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surface mesh you
can use the Modify
geometry >
Surface remesh
option on the object.

Introduction to Simufact Forming 27

Preprocessing
Importing geometries from results
◆ Geometries can also be imported with results
and with a mesh from certain time steps of a
specific process.
▪ This process can also be part of other
projects.
◆ This way it is also possible to import
geometries from Welding or Additive projects. In the infosheet
‘TransferWeldingFor
◆ Only the .sfp, .swproj or .amproj files have to ming’ an example is
be selected and it is displayed automatically shown, where
geometries from a
for which timestep the results are available. Welding simulation
are imported to start
a simulation in
Forming.

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Introduction to Simufact Forming 28
Preprocessing
Positioning components in Simufact Forming
◆ Typically, the tool positioning should be done in
the CAD system. However, Simufact Forming
offers some positioning operations in the model
set up.
◆ There are three different concepts available:
▪ Manual positioning (Drag arrows directly) You can access
the positioning menu
▪ Direct positioning (Move by x mm, Rotate from the context
by y degrees) menu of the desired
▪ Positioning via bounding box (Align to other component in the
bodies) model view or in the
process tree.
▪ Contact positioning (Positioner)
◆ Every model component is surrounded by its so- The bounding
called bounding box. box does not rotate
◆ The edges of this box are parallel to the global with a component. It
coordinate directions and its dimensions are is always aligned
determined by the maximum dimensions of the parallel to the global
axes!
component in the corresponding direction.
◆ You can easily align bodies relative to each other

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by positioning them according to the min, max or
center dimensions of their bounding boxes.
◆ You can also align it/move it to special locations
such as the origin or defined points.

Introduction to Simufact Forming 29

Preprocessing
Utilizing the automatic positioning feature
If sub-stage 2 is
◆ Simufact Forming offers the so-called sub-stages. active and you are
◆ They can be used to automatically position components. using the tool
positions at their
◆ For example you can draw your tools at their bottom dead center (BDC) and the BDC you can define
sub-stages will automatically position the workpiece in the tool and open the tool a stroke of 0 mm to
accordingly. enable an automatic
◆ This can only be used if the main forming direction is the z-direction. calculation. It is then
calculated auto-
◆ For more information about this please see the infosheet or watch the Quickstart matically as the
FE Video Tutorial. distance between
◆ Sub-stages are especially useful in combination with the stage control. See the BDC of the press
“Advanced” chapter of this tutorial for more information. controlled die(s) and
its position after sub-
stage 2.
Substages 1 and 2:
In FV
Positioning tools simulations and
some FE processes
not all sub-stages
Substage 3: Forming are available.

The sub-stages

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Substages 4 and 5: are a powerful tool
Removing tools (allow for a more
comfortable model
elastic spring back) setup.

Introduction to Simufact Forming 30

Preprocessing
Forming machines and tool movements: Presses
◆ Simufact Forming aims to be a software For each default
that keeps close to the actual press you can find
manufacturing processes. additional
◆ Therefore it offers a variety of the most information in the
infosheet linked in
common forming machines to control the the dialog!
tool movements:
▪ Crank press, Hammer, Screw press, In the press
Hydraulic press and more… dialog you can view
the plot to see the
◆ They are set up with their machine specific movement the press
parameters (e.g. crank radius, rod length will do with the
and revolutions per minute for a crank current settings.
press, max. energy for a hammer,…)
◆ Presses are added to the object catalog All of the
and then assigned to the process. Then the standard presses
can move tool(s)
moving tools are assigned to the press. only in z- or –z-
◆ Typically the forming direction is the –z- direction. For move-
direction. ments in other
directions you will
◆ Non-standard movements can be achieved

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have to use the
by using table presses and / or local press type Tabular
coordinate systems. motion.

Introduction to Simufact Forming 31

Preprocessing
Representation of physical interactions: Friction
◆ Physical interactions between the components in the model are described
mathematically.
Simufact
◆ There are three main points where these interactions are defined in Forming also comes
Simufact Forming. with a library of
friction objects which
◆ Friction: are mainly based on
▪ Friction is an important factor in metal forming processes and can our experience and
influence material flow and forming forces substantially. are a good place to
start your simulation
▪ The friction definition is covered in Simufact Forming by the friction with.
object which is assigned to a die. They determine the occurring friction
stresses. For detailed
information about
▪ There are multiple friction laws available that the user can choose the friction modeling
from. You can set up the parameters manually or use an automatic in Simufact Forming
please see the
functionality (only available for general steel materials). respective chapter
of the Application
tutorial.

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Introduction to Simufact Forming 32
Preprocessing
Physical interactions: Thermal properties
The automatic
◆ The thermal properties of a calculation of the
component govern the distribution heat transfer
and transfer of heat between the coefficient (HTC)
model components and to the from die to
surroundings. workpiece takes the
contact pressure
◆ Each component needs an assigned between the two
temperature object to define these components into
interactions. account.
◆ Simufact Forming offers default
values for all coefficients and The default
dissipation factor is
automatic calculations for some of 90%.
them. Alternatively, all of them can
be manually defined (as a constant Assigning an
or a temperature-dependent table) initial temperature to
by the user. a component does
not change its
◆ During forming processes the dimensions! To go
forming energy is largely converted from cold to hot
into heat. This so-called dissipation dimensions you can

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factor is a material property and can use the Heat up
be modified directly in the material function in the
context menu of an
object. object!

Introduction to Simufact Forming 33

Preprocessing
Contact and contact tables
◆ There are a few important things to know If a component
about contact calculation in Simufact simply vanishes at
the start of a
Forming. simulation it is
◆ There is no contact between rigid dies! probably not
correctly defined in
They can penetrate each other without the contact table!
effect.
◆ If there are only rigid dies and a Contact should
typically only be
workpiece in the model, it is assumed by defined in one
default, that all dies can contact the direction. From the
workpiece. finer meshed body
to the coarser
◆ If there are multiple deformable bodies in meshed body.
the model, a contact table has to be set
up where all possible contact situations For some
between the components have to be examples of the use
of contact tables
defined manually. please see the more
◆ Additionally the contact table can be used advanced examples
in the Application

Copyright © simufact engineering gmbh

to gain access to more advanced contact tutorial. E.g. the
settings (contact tolerances, glue contact, flanged socket head
etc.). bolt.

Introduction to Simufact Forming 34

Preprocessing
Meshing technologies and areas of application
◆ Every FE simulation needs a FE mesh for the deformable bodies Quad elements
◆ Simufact Forming offers multiple element types and different meshing are the only option
techniques. The available options are: for 2D simulations.
You can choose
▪ 2D: Quad elements (Element type 3, 10, 11) between the two
➢ Advancing Front Mesher, Quadtree Mesher meshers for different
➢ Basic 4 Node 2D Element meshing strategies.
▪ 3D: Hexahedron (Element type 7)
➢ Hexmesher, Sheetmesher, Ringmesher FV simulations
do not work with an
➢ 8 integration points, highest accuracy, highest cost
FE mesh. Therefore
➢ Recommended for meshing of the workpiece! the in this case used
▪ 3D: Solid-Shell (hexahedron geometry, Element type 185) surface mesher is
➢ Sheetmesher not listed here as it
technically does not
➢ Special mathematical formulation for selected sheet metal applications
create finite
▪ 3D: Tetrahedron (Element types 134) elements but
➢ Tetmesher surface facets.
➢ Only one integration point, fast calculation
➢ Inaccurate depiction of plasticity You can find
➢ Only recommended tools in die analysis! detailed descriptions
of the different

Copyright © simufact engineering gmbh

▪ 3D: Tetrahedron (Element type 157) element types in the
➢ Tetmesher Technical reference
➢ 4 integration points, more expensive in Marc Vol. B.
➢ Only recommended if hexmesher fails!

Introduction to Simufact Forming 35

Preprocessing
Refinement and remeshing
◆ All meshers delivered with Simufact Be careful with
Forming support the use of so-called increasing
refinement boxes. refinement levels.
▪ Define regions of interest in your The number of used
elements will rise
model and refine your mesh in that exponentially!
area only.
▪ Each refinement level halves the Using the
original element edge size. surface refinement
boxes is generally
◆ During a forming process, the elements the recommended
get distorted. option. Full
◆ Big distortions have a negative impact on refinement is only
Distorted Elements needed in special
the result quality or can lead to errors
cases.
during the calculation.
◆ To ensure best results and stable Simufact
calculations, Simufact Forming can Forming uses
remesh
perform automatic remeshings during the sophisticated
process. algorithms to map
the results from the
▪ You can control when and how a

Copyright © simufact engineering gmbh

Deformed geometry New mesh with same old mesh to the new
remeshing is performed in the with excessively topology and regular
one to ensure an
distorted elements elements
settings of the remesh object . optimal transfer.

Introduction to Simufact Forming 36

Preprocessing
Defining process and numerical parameters: Forming control
Keep in mind
◆ All of the general simulation settings are combined that writing results
for each process in the so-called Forming control. more frequently
requires more disk
◆ Here you can define the termination criteria of the space!
simulation (stroke, time, force,…) and activate or
deactivate sub-stages (automatic positioning). Deviating from
◆ You can also access many numerical parameters if the automatic time
step control is only
you need to adjust them. The most important are: necessary for
▪ Output divisions: Control how frequent result special processes.
Setting manual time
files are written. steps can speed up
▪ Output results: Activate special output results the simulation but
can also
that are not activated by default. compromise the
▪ Step control: Control the time step size during results!
the calculation.
Activating
▪ Parallelization: Activate parallelization options parallelization
to significantly speed up the calculation. options is strongly
recommended for
▪ Advanced: Advanced numerical parameters

Copyright © simufact engineering gmbh

3D simulations
which should only be touched by experienced exceeding 10000
users. hexahedron
elements!

Introduction to Simufact Forming 37

Preprocessing
Model check, warnings, errors and advice
◆ Right before starting a simulation, Error
Simufact Forming runs an
automated model check to see if You can run the
model check
everything is in order. separately by using
◆ If something is amiss, the model the icon in the
bottom tool bar.
check will prompt error or warning
messages as well as practical The model
advice on how to proceed. check can‘t catch all
◆ If the model contains an error, the errors prior to
starting the
simulation cannot be started until the simulation. However
issue is fixed. Warning it gets updated with
each version of
◆ If the model check shows warnings, Simufact Forming!
the simulation can be started
anyway. However, you should read If there are
the warning messages carefully and multiple errors or
warnings you can go
decide for yourself if you want to through them with

Copyright © simufact engineering gmbh

ignore it. the arrow buttons.

Introduction to Simufact Forming 38

 Basics tutorial

Calculation

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back to p.1
Introduction to Simufact Forming 39
Calculation
Doing the math The
convergence
◆ Nearly all the information that was gathered monitor can be used
while setting up the model is written in text to quickly evaluate
form into a so-called .dat file. the numerical quality
◆ This file is read by the solver program and is of the simulation. It
gives a quick
the basis for the calculation. overview of the
◆ The solver calculates a result for each number of cycles
increment (defined by the step control). that are needed per
◆ During the calculation, the solver writes some Solver increment as well as
(calculating) the convergence
informational output for the user: behavior of the
▪ The status file (*.sts) primarily reflects the K
simulation.
• Assembly of u = K −1 F
progress of the simulation. It logs • Solving of (FE)
completed increments as well as remesh 𝜕𝑄 Marc comes with
• Solving of 𝜕𝑡 + 𝛻𝐹 = 0 (FV) multiple matrix
operations and displays the total wall • Strain solvers. You can
time after finishing. • Stress select which one to
▪ The output file (*.out) contains detailed • Force use in the Advanced
• Total equivalent plastic strain settings in the
solver specific output throughout all
•… Forming control.
stages of the simulation.
▪ The log file (.log) contains selected solver

Copyright © simufact engineering gmbh

For more
specific information as well as Access the information on this
information about additional programs solver output topic please see the
that are called during the simulation (e.g. from the GUI: Technical reference
in Marc Vol. A.
meshers).

Introduction to Simufact Forming 40

Calculation
Running the solver
◆ After the solver has been started, you can
safely close the Simufact Forming GUI.
Solver calculation will not be stopped, Caution: If the
because it is executed on another core solver runs locally,
the machine itself
process. has to be running
during the whole
duration of the
◆ Furthermore, Simufact Forming offers the process.
possibility to run the Graphical User
Interface (GUI) locally and the solver When using the
remotely in the background on a different solver remotely, the
client machine can
machine. This enables the usage of be shut down
powerful central computer resources for without interrupting
the simulations. Especially for long the solving process
on the remote
running simulations it can increase the server.
stability to use dedicated computers.

Copyright © simufact engineering gmbh

Introduction to Simufact Forming 41
Calculation
Remote calculations with Simufact Remote
◆ Simufact Forming comes with an
additional software called Simufact
Remote which allows for an easy
remote simulation management.
For detailed
◆ The result files are automatically instructions on how
synchronized between client and server to set up a remote
environment please
so that no manual copying of files is refer to the chapter
necessary. „Remote“ of the
Simufact Forming
◆ While the forming GUI only runs in Installation Guide.
Windows environments, the solver and
therefore the calculation can be done A lot of
on Linux systems as well. information can also
be found in the
◆ More information can be found in the multiple infosheets
Installation Guide. linked directly in the
remote manager
application.

Copyright © simufact engineering gmbh

Introduction to Simufact Forming 42
Calculation
Organizing simulations with Simufact Monitor
◆ As available licenses and computing capacity
are generally limited it is important to keep
track of your running simulations.
◆ Simufact Monitor gives you an overview of Simufact Monitor
the recently performed and currently running can run and start
simulations without
simulations on your computer and provides a having to have the
queue to manage future simulations. project opened in
the GUI.
◆ Keep in mind that the queue feature is
currently limited to the local host and is not a
Use the
replacement for a sophisticated network Scheduling settings
queuing system. of the monitor to
control how many
◆ You can use Simufact Monitor when you calculations should
select Queue analysis when starting the be run at the same
simulation from the GUI. time.

Copyright © simufact engineering gmbh

Introduction to Simufact Forming 43
Calculation
Parallelization options in Simufact Forming Models with
more than 10000
◆ Multi-core processors have been the Hex-elements can
standard for many years now. benefit massively
from parallelization.
◆ To make use of more than one core at once
you will have to parallelize your simulation Excessively high
between multiple cores. parallelization
settings can actually
◆ Simufact Forming offers two possibilities: slow down the
▪ Domain Decomposition Method simulation as the
communication
(DDM): Divides a model into smaller between the used
parts (domains). Each domain is cores may take
calculated by a separate core. This more time than the
actual calculation.
method gains efficiency the bigger the
model gets (the more FE elements it DDM is not yet
has). not parallelized supported for FV
▪ Shared Memory Parallelization (SMP): calculation time for simulations!
each increment
Distributes the assembly and solution of with DDM
over-head Find more
the matrix equation systems to multiple detailed information

Copyright © simufact engineering gmbh

cores. about this topic in
the infosheet linked
◆ Parallelization can drastically reduce under Forming
simulation time and increase your efficiency control >
when working with Simufact Forming! problem size / number of elements Parallelization!

Introduction to Simufact Forming 44

 Basics tutorial

Postprocessing

Copyright © simufact engineering gmbh

back to p.1
Introduction to Simufact Forming 45
Postprocessing
Visualizing results of the calculation
Use the context
◆ Just like the preprocessing earlier, the menu to change the
visualization of
postprocessing is done in the Simufact components directly
Forming GUI. in the result view!
◆ Double click the icon in the process
You can hide the
tree to open the result animation window. process tree and
◆ You can display the simulation results as a object catalog to
function of the simulation progress (time, have more space for
your animation
stroke, increment,…) and view it as an window.
animation.
◆ There is a wide variety of result values You can save
the process
available which you can select directly in the animation to a video
animation window. file for presentation
purposes!
◆ By default, the result values are mapped
over the surface of the workpiece and shown You can open
as a so-called contour plot. Some result multiple result
values are also available as vector plot ( ). windows and

Copyright © simufact engineering gmbh

automatically
◆ The result view can be modified by the user synchronize the
in many ways (legend settings, background views to easily
color, size and position of GUI elements). compare result
values.

Introduction to Simufact Forming 46

Postprocessing
Evaluating integral process values: the THS-Plot
You can freely
◆ The history plot (also called time history (THS) plot) displays integral change the axes
process values such as forces or energies as a graph. limits and select
displayed units.
◆ Click the icon in the top tool bar to open it. Use the arrow on the right
to add the results of multiple processes to a single THS plot! You can
◆ You can check the progress of forming forces, die movements and simultaneously view
the results of
velocities and much more as a function of the simulation progress (time, multiple simulations
stroke, increment,…). in one THS-plot by
clicking the arrow
◆ There are many comfort functions to adapt the display of the graphs to your next to the icon in
likings. the tool bar and
selecting the plot to
◆ From here you can also export these results as a .csv-file to further which the new result
evaluate the results in a table handling software of your choice. should be added!

The THS-plot
can sum up,
average and adapt
curves to symmetry
angles for you!

Copyright © simufact engineering gmbh

Please find more
information in the
linked infosheet!

Introduction to Simufact Forming 47

Postprocessing
Utilizing particles, post-particles and flowlines
Excessive
◆ Particles and post-particles are points that numbers of particles
can be freely defined in the model which or points for
follow the material flow and can as such be flowlines can slow
down the GUI as
used as tracking points. well as the
◆ You can select which result values should simulation and result
in increased result
be stored for the defined particles. file sizes.
◆ Flowlines behave in the same way but can
not store any result values besides their For more
own position. They are exclusively used to information on how
to create and use
track material flow over the course of the the post-particles
simulation. please see the
infosheet linked in
◆ The position of these points or flowlines is the creation dialog!
not influenced by the mesh or remeshings!
◆ Particles and flowlines have to be defined For an
application example
during the preprocessing. of particles and
◆ Post-particles however can be defined when flowlines please see

Copyright © simufact engineering gmbh

the example
the simulation is already finished! Tutorial > Hot
◆ Their results can be viewed in the THS plot Particles forging > Drawing
or exported as a .csv-file. lug!
Flowlines

Introduction to Simufact Forming 48

Postprocessing
Taking a look inside: Clipping planes
◆ Simufact Forming offers an easy
creation of various combinations
of clipping planes which allow you
to take a look at the results inside
the workpiece.
◆ You can add planes normal to any If you cut
desired direction. components when
their mesh is
◆ Their position can be changed displayed, you see
comfortably in the view by triangular facets in
the cut view. This is
dragging the planes to the desired not the shape of the
position or by entering a specific finite elements but
position in the creation dialog. rather new surface
facets that are
◆ You can save cutting plane temporarily created
positions and contours to the to display the cutting
plane.
object catalog to reuse or export
them.

Copyright © simufact engineering gmbh

Introduction to Simufact Forming 49
Postprocessing
Tools for measuring and querying
You can select if
◆ One of the main goals of the the measuring tool
simulation is to predict the exact should catch nodes
or if it can be an
shape of the formed workpiece. arbitrary point on the
◆ To accurately meter model surface.
dimensions Simufact Forming
provides a Measuring tool. You can directly
enter coordinates in
◆ This tool can measure distances, the measuring tool,
angles and radii. and they will be
displayed in the view
◆ It can show you the delta values window.
along the global axes, or the center
point of a circle. With right-
clicking on a query
◆ You can use the Query tool to point in the view you
display result values for single can access its
nodes of the FE mesh. display settings.

◆ You can create lists of result points See also the

and create path plots of that list. infosheet linked in

Copyright © simufact engineering gmbh

the Measuring
◆ Query points can also be dialog for a
synchronized between multiple description of all
result windows. functionalities!

Introduction to Simufact Forming 50

Postprocessing
Documenting your efforts: Process reports
◆ Documenting your simulation work is a
good habit but can be quite exhaustive.
To add
◆ To support you in your documentation snapshots to your
efforts, Simufact Forming offers the so- report just use the
context menu in the
called Process report. result view and
◆ This html-style report gathers all of the select Add to
process report.
most important information about the
model setup as well as the results of the You can edit
simulation and creates a tabular overview. these snapshots
later. You can
◆ You can control what information should rearrange them,
be written and what should be omitted. delete them or edit
◆ Furthermore you can add snapshots of the their description.

result view to the report and add your own

You can print the
notes to them. report or save it as
◆ The comments from the comment box in an .html file. You can
comfortably view
the process selection dialog will be in the them with any web

Copyright © simufact engineering gmbh

report as well. browser!

Introduction to Simufact Forming 51

Postprocessing
Exporting results from Simufact Forming
◆ Simufact Forming offers multiple options The .unv export
to transfer simulation results to different is only available for
programs for further processing. FE results!
◆ By default, Simufact Forming writes the
results in its own proprietary file format. FE results with
(see Infosheet inside coarsening
Transfer Simufact should not be
‘ExtractSimulationResultsFromArc’) result files exported as .unv
◆ You can import these result files into files as the used
Simufact Welding to append a welding Results to other tying conditions are
simulation to your forming simulation. not exported and the
FE programs as mesh would be
◆ If you want to use non-Simufact software, .unv files corrupt. You can
you can use the UNV interface. deactivate the inside
coarsening in the
◆ You can export selected results (of FE Meshes to other
meshing dialog!
simulations) as a .unv file which can be applications as
read by most FE programs. .bdf files .unv files as well
◆ Furthermore, you can export geometries as .bdf files can also
as .stl files, meshes as .bdf files as well Geometries as .stl be imported to
as most tabular data as .csv files. Simufact Forming
files

Copyright © simufact engineering gmbh

via the object
◆ 2D contours created with the clipping tool catalog: Geometry
can also be exported in the .igs format. Tabular data as > Mesh from file
.csv files

Introduction to Simufact Forming 52

Postprocessing
Result data management
◆ Storing all results of every completed
simulation will require a high amount of
disk space.
Thin out settings
are saved for the
◆ The amount of required disk space user.
depends on the number of elements
and the output interval frequency and If the settings
can therefore rise very fast. are already defined,
the user can thin out
immediately.
◆ The result data can be managed within
Simufact Forming with a right-click on The additional
Project > Thin out project. process result
options are applied
and any spr/result
◆ In the settings dialog, the user can file which does not
define which data should be kept and match the defined
decide how *.spr files should be treated. options will be
removed.

Copyright © simufact engineering gmbh

◆ Please be aware, that any removed
result can’t be restored without
rerunning the simulation!

Introduction to Simufact Forming 53

 Basics tutorial

Advanced modeling techniques

Copyright © simufact engineering gmbh

back to p.1
Introduction to Simufact Forming 54
Advanced modeling techniques
Keeping an overview in big projects
◆ Simufact Forming provides some Process
comfort functions to keep bigger filter
projects nice and tidy. Note the change
◆ The key are the different filter in the project icon at
the top of the
functions. process tree when a
◆ You can use the process filter to filter is active. It
hide processes that clutter the shows how many
processes are
project but are not yet ready to be visible.
deleted.
◆ Furthermore, you can apply filters Object You can sort the
to the catalog to hide/show only filter items in the object
catalog either by
certain objects. E.g. show only their name, their
press objects or show only objects modification date or
in reverse by
assigned to a certain process. clicking on the Sort
◆ To quickly clean up a cluttered entry in the object
catalog context
object catalog you can use the menu.

Copyright © simufact engineering gmbh

Remove unused command via the
context menu entry of the catalog.
This removes all objects which are
not assigned to any process.

Introduction to Simufact Forming 55

Advanced modeling techniques
Creating and automating process chains
By default, the
◆ A majority of forming processes position of the
workpiece is not
requires multiple stages until the changed when
product has its desired shape. transferred from one
process to the other.
◆ To accomplish this, Simufact Forming
allows you to extract results from every You can
process and use these for the next manually define
stage of your process chain. translations and
rotations between
◆ You can do this manually or set up a every stage.
so-called stage control.
◆ The stage control connects the single The stage
control also supports
stages of your forming process chain. 2D > 3D transitions!
It automatically transfers the results of
the previous stage to the next one and You can find
runs the simulation. many processes
utilizing the stage
◆ You can set up complete multi stage control feature in the
processes and start the whole chain Demos&Examples.

Copyright © simufact engineering gmbh

For example in the
with a single click. category Cold
forming >
Multistage
processes!

Introduction to Simufact Forming 56

Advanced modeling techniques
Expanding of axisymmetric Geometries
◆ 2D and 3D axisymmetric Geometries
can be expanded around the symmetry
axis.
◆ One option is the ‘Expand results’
button in the result toolbar. The
geometries and the results get
expanded by a certain degree. Results also get
▪ The expansion angle can be expanded if present.
specified in the ‘Result expansion’
tab in the settings. To import a
geometry with
▪ This is possible for 2D and 3D results, right-click in
results. the object catalog
▪ The expanded geometry can then and select
‘Geomatries‘ →
be saved in the object catalog. ‘From results‘
◆ Geometries can also be expanded
directly in the object catalog via right-
clicking → ‘Modify geometry’
▪ For a 3D sector select ‘Expand 3D

Copyright © simufact engineering gmbh

sector’
▪ For a 2D geometry select ‘Rotate
axis to 3D’

Introduction to Simufact Forming 57

Advanced modeling techniques
Spring-loaded dies and other applications of springs When using
springs together with
◆ Generally speaking, springs in Simufact a segment
Forming are objects that apply a force on symmetry in your
model you should
a body. make sure, that the
◆ The applied force is defined by an initial option Adapt forces
force, a spring stiffness and a direction. and energies to
workpiece symmetry
◆ Two types of springs are available: is checked in the
forming control!
▪ Die spring: They are typically used to
model spring-loaded dies in forming To use local
processes. They can apply forces in coordinate systems
global coordinate directions and have you will need a so-
called die insert!
a fixed range of deflection.
Typical application: Blank holders Generic springs
▪ Generic spring: They apply forces on are not available in
a die in the global coordinate FV simulations!

directions or along the axes of a local

For detailed
coordinate system. They can apply information about

Copyright © simufact engineering gmbh

rotational torques or use a special the topic of springs
stabilizing function. However, you please see the
respective chapter
cannot define a maximum deflection. of the Application
Typical application: Press elasticity tutorial!

Introduction to Simufact Forming 58

Advanced modeling techniques
Non-standard die movements: table presses, kinematics
For more
information about
◆ Typically the default forming and press table presses,
direction in Simufact Forming is the –z- rotation axes and
direction. local coordinate
◆ If you need to deviate from that you can systems please see
the relevant part of
use the so-called table press. the ring rolling
◆ The table press can move dies in any chapter in the
global coordinate direction as well as Application tutorial!
prescribe rotational movements.
You can find
◆ Combined with a local coordinate system specific information
and a die insert, the table press can about the kinematic
prescribe movements in any possible modules by clicking
direction. Open tutorial in the
relevant
◆ There are more complex forming Demos&Examples
processes however which require model!
specifically developed kinematics. For
example: You can create
▪ Open die forging (Cogging, radial your own kinematics
forging, shell forging, etc.) using the so-called

Copyright © simufact engineering gmbh

user-defined
▪ Ring rolling (RAW, MERW, …) kinematics. Please
◆ These are accessible through the relevant see the Scientific
tutorial for more
application modules. information!

Introduction to Simufact Forming 59

Advanced modeling techniques
Die load analysis For complete die
load analyses you
◆ Simufact Forming offers extensive need to use
possibilities to simulate the load on your dies. deformable bodies
for the dies.
◆ You can calculate many determining factors
which might reduce the lifespan of your dies
Contact
or the accuracy of your product. Such as: pressure and die
▪ Contact pressure wear can be
calculated for rigid
▪ Internal stresses dies as well.
▪ Elastic deformation
▪ Abrasive die wear Fully coupled
analyses come with
▪ Temperature very high
◆ Simufact Forming allows decoupled die load computational costs.
Decoupling them
analyses where the simulation of these loads saves a lot of
and the simulation of the actual process are ressources.
separated. This increases simulation speed
and efficiency significantly. See the „Die
◆ Calculation of die loads is also used to wear, die load and
reinforcement“
predict the strength of reinforcements, which

Copyright © simufact engineering gmbh

tutorial chapter for
is state of the art for most cold forming extensive
applications. information about
this topic!

Introduction to Simufact Forming 60

Advanced modeling techniques
Optimization: Parameter identification, Geometry variation
◆ Calibrating and optimizing simulation
parameters can be a very time-
consuming task.
◆ Simufact Forming offers an optimization
feature which can automatically create You can find
various variants of processes. some examples of
optimization cases
◆ The two main features are: in the
▪ Parameter identification: Demos&Examples
Simulation parameters such as the under Tutorial >
friction coefficient or the heat Optimization!
transfer coefficient are varied over
the course of numerous Please find more
information about
simulations to approach a defined the optimization
goal (e.g. workpiece temperature). possibilities in the
Different optimization strategies respective chapter
are available. of the Application
tutorial!
▪ Geometry variation: Simufact
Forming can exchange geometries

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over the course of multiple
simulations and evaluate the result
quality.

Introduction to Simufact Forming 61

 Basics tutorial

Troubleshooting

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back to p.1
Introduction to Simufact Forming 62
Troubleshooting
Exit codes
◆ When the simulation ends, the solver will write
an exit code at the end of the .out, .log and .sts Please see the
respective infosheet
file. for a complete list of
◆ Along with the exit code a message will be all exit codes and
their description.
displayed describing the reason for the end of There you will also
the simulation. find some advice on
how to resolve the
◆ A successfully finished simulation will end with issue.
exit code 3004.
◆ All other exit codes indicate an error during the
simulation which caused a premature stop.
◆ In case of an unexpected solver crash no exit
code can be written.
◆ In addition to looking up the exit code in the
infosheet you may want to search for error You can find
messages in the .out and .log files. every infosheet via
Access the Help > Infosheets >
◆ Therefore simply open these text files in a text solver output Simufact Forming.

Copyright © simufact engineering gmbh

editor and search for the “error” keyword. from the GUI: This one is called
Exit_codes_en.pdf.

Introduction to Simufact Forming 63

Troubleshooting
File structure: working and result directories
◆ A complete Simufact Forming project always consists If you move a
of both the .sfp-file and a folder with the same name. project on your hard
disk or want to pass
◆ This folder contains all of the information about the it on to someone,
project. make sure to always
keep the project
◆ In PROJECT/project name/… you will find the single folder and the
processes of your project as well as the corresponding .sfp
AdditionalFiles folder. file together!

◆ A process folder contains, amongst other, the _Log_,

If you are in
_Results_ and _Run_ directories. contact with a
▪ The _Run_ directory contains all information that Simufact support
employee you might
is necessary for the solver to be able to calculate be asked for the
the model. contents of your
_Run_ directory.
▪ The _Results_ directory contains the result files
after they have been imported by the GUI. The _Run_
▪ The _Log_ directory contains a .log-file which directory contains
records all actions of the GUI during the amongst others the

Copyright © simufact engineering gmbh

.sts, .log and .out
calculation. files as well as the
.dat-file.

Introduction to Simufact Forming 64

Troubleshooting
Licensing You can check
your license
◆ Licence server (service) provides the license → MSC Licensing. situation via Extras >
Options > Global
◆ It comes as a separate download, installation and documentation.
settings > Licenses.
◆ Environment variable MSC_LICENSE_FILE=port@server is generated
during the installation process and can be changed later via your OS. If the program
does not start due to
◆ You can check your license status in the Simufact Forming GUI. a missing license
From Simufact Forming: you can access this
page by clicking the
List of all possibly available details button of the
license features. error message.
From Simufact Forming:
Required maintenance end If the shown
date (or later) of the license dialog page does
version. not open or opens
From the license server: very slowly, the
license server is
Type of a valid license – all
probably not
invalid, expired or not available.
available licenses show the
type “unknown“. For

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From the license server: troubleshooting with
Number of currently and the licensing please
overall available licenses as see the MSC
well as the users who are using licensing
them. documentation!

Introduction to Simufact Forming 65

Troubleshooting
System environment when using Simufact Remote
client side server side
License check*
License server
management
Remote GUI Remote GUI
Parts of the
environment with the
License check*

License check*
dashed outline are
Simufact service only needed for
remote calculations.

Settings Settings If you encounter

a persisting problem
with any Simufact
product, feel free to
contact our support
team. For more
Simufact Forming control and files for
local simulation Solver information please
GUI see the support
section on
www.Simufact.com!

Copyright © simufact engineering gmbh

MPI service
Data
(for DDM)
management
*checks for MSC_LICENSE_FILE environment variable

Introduction to Simufact Forming 66

 Basics tutorial

Simulation quality

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back to p.1
Introduction to Simufact Forming 67
Simulation quality
Don‘t just check
Checking for plausibility the final result.
Some errors may
◆ A simulation is the solution of a mathematical Incorrect flowcurve data only be visible
problem. during certain
stages of the
◆ The solution achieved can only be as process.
accurate as the input that was used to
describe the problem. Use the THS
plot to check tool
◆ Wrong input data can have obvious effects movements, forming
on the simulation but they might be more forces or the
subtle as well. No plastic strain at workpiece volume.
unrealistically high stresses
◆ Simufact Forming tries to ensure that the Apart from
input data is correct (e.g. automatic unit wrong input data
conversions and model checks). Numerical issue numerical problems
are possible. Check
◆ However you should always critically check the mesh for
your results: deformations or
dramatically
▪ Are the tool movements (velocities) increased local
correct ? result values (so-
called hotspots).
▪ Is the material flow realistic?

Copyright © simufact engineering gmbh

▪ Are the forming forces or effective Use the .sts-file
stresses in a reasonable range? to check the
Single node sticks to convergence
▪ Are the temperatures as expected? tool edge. behavior of the
simulation

Introduction to Simufact Forming 68

Simulation quality
Calibrating the simulation
◆ When setting up a simulation model a lot of assumptions are made about Calibrating your
all the boundary conditions and input parameters that are used. simulation is import
to achieve reliable
◆ To achieve the best possible simulation results you should calibrate these results.
parameters so that the results fit the reality as well as possible.
◆ Best practice is to start your simulation efforts with a part that is currently It is not
produced by your company and of which the production process is running recommended to
directly start your
without bigger issues. simulation efforts
◆ Calibrate your simulation model in such a way that it fits this real part. with a problematic
part that is causing
◆ Then you can use these calibrated parameters for your future simulations issues during
and achieve reliable results! production. Use a
well running part to
Define correct tool calibrate the
Start with
movements. They Simulated simulation first!
a Simulated Use simulation
should be velocity or geometry
currently Yes forces fit real Yes to predict new
stroke controlled. No fits real
produced measurings? parts! You can do
force control on the first part?
part. sensitivity studies to
try!
see which
No

No parameters have a

Copyright © simufact engineering gmbh

negligible effect on
Adapt material
Calibrate the model your process and
data (flow curve
(adjust stroke, friction, scaling) which are crucial!
temperature settings,
numerical parameters)

Introduction to Simufact Forming 69

 Basics tutorial

User customization

Copyright © simufact engineering gmbh

back to p.1
Introduction to Simufact Forming 70
User customization
Employing the library feature of Simufact Forming Adding objects
from a library to the
◆ Simufact Forming does not only come with an object catalog
extensive material library but offers more libraries for creates copies of the
object which are
e.g. friction objects or press objects. independent from
◆ The settings for these objects are based on literature the original library
data or our experience. entry.

◆ In addition to these, you can create your own libraries. You can create
◆ The library feature follows a certain structure: copies of items in
the Simufact master
▪ Simufact master library: Comes with Simufact library if you want to
Forming. You cannot change the items, but they edit them.
might be changed with new versions of Simufact
Forming. New versions of
Simufact Forming
▪ User master library: A library that can be filled will not affect the
with objects by and for the user, so they are user and common
master library!
readily available for new projects.
▪ Common master library: A shared library between You can find the
multiple users (usually a network drive). library settings in the

Copyright © simufact engineering gmbh

Global options.
Commonly used objects (e.g. presses) can be Please see the
stored here and every Simufact user in the infosheet linked in
network has access to them. the dialog for further
information!

Introduction to Simufact Forming 71

User customization
Facilitate repetitive tasks with project templates
◆ Often times you don’t create a completely
new project but rather change smaller
aspects of already existing ones (e.g.
exchange a geometry).
◆ To speed up this process Simufact Forming
offers the possibility to work with project
templates.
◆ You can save every project as a template via Please note that
File > Save project as > As template. the template is only
safe from
◆ The project is saved without results in the overwriting if it is
template directory of Simufact Forming. opened via File >
Open template.
◆ You can open a template via File > Open
template.
◆ You can now adapt the project to your
needs, save it under a new name and run
your simulation without having to set up

Copyright © simufact engineering gmbh

everything again.

Introduction to Simufact Forming 72

User customization
User-customizable GUI and global settings
◆ Simufact Forming can be customized in many Most dialog
aspects. pages in the global
settings dialog have
◆ You will find all global settings in the menu bar their own infosheet.
via Extras > Options > Settings. Click the button on
the bottom right for
◆ For example, you can choose between multiple more information
GUI languages. about the possible
settings.
▪ e.g. English, Japanese, German, Russian
and more
All settings are
◆ You can customize the content of the GUI in stored for each user
many aspects: under the directory
%appdata%\Simufac
▪ Define default values, for directories, color t\simufact.formin
g_<version> in the
legend settings, result values or third-party simufact.forming.
programs ini and
simufact.forming_
▪ Change the appearance of the view area <version>.ini. You
such as default colors, 2D to 3D expansion can copy these files
settings, flow line or particle display to a different

Copyright © simufact engineering gmbh

installation to set up
options the same
configuration.

Introduction to Simufact Forming 73

User customization
User-customizable unit systems

◆ Simufact Forming can also be individually

customized to provide results in different unit
systems.

◆ You will find unit settings in the menu bar via There are 5
Extras > Options > Settings > Unit/Unit system predefined unit
systems available:
Simufact default,
◆ Other unit setting combinations can be defined in International system
the user defined unit system. of units (SI-m
system), SI-mm unit
system, Imperial unit
system, United
◆ The input and output values in Simufact Forming states customary
always have corresponding units which you can system
choose as you desire. Simufact Forming internally
takes care that all values are in consistent units.
The same Forming projects may be used by

Copyright © simufact engineering gmbh

different users with different units. This is different
from many general FE programs, where the user
is responsible to maintain consistent units.

Introduction to Simufact Forming 74

Introduction to Simufact Forming
75

Copyright © simufact engineering gmbh