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FORGE® NxT for the Aerospace Industry

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Aerospace forged components producers face the challenges of designing, testing and delivering their products on-time and on-budget together with producing parts complying with the in-use properties requirements.

Since the beginning, TRANSVALOR has been working closely with major European engine and aerospace components producers to develop an advanced simulation solution for high technology forged components. FORGE® NxT is now used by key producers worldwide to design engine parts such as pressure disks or fan disks or fans, landing gears, fuselage parts. FORGE® NxT is the solution to minimize real scale tryouts and reduce cost while designing high quality components meeting performance requirements.
 

“FORGE® meets the growing demand for quality and development time since all our processes are modeled and optimized through simulation before manufacturing. The material flow of our non-iron metals like Titanium and Aluminum can easily be tracked and tools optimized to reach better results. Furthermore, the great flexibility of the software allows advanced self-programming for fast preprocessing procedures and new processes ideas are easily implemented into the software, giving Otto Fuchs a strategic advantage in the aeronautical and automobile fields.”

Mauricio Santaella
FEM-Analysis & Forging Simulation
Otto Fuchs KG
Meinerzhagen, Germany


Born in aerospace FORGE® NxT includes many innovations that makes it an accurate and reliable simulation tool for the design of high-technology forged components.

Models and Data

Wide range of models and specific data for the aerospace industry are integrated into FORGE® NxT:

  • Material behaviour, viscoplastic, elasto-viscoplastic, elasto-plastic laws are available. The extensive material database includes data for nickel based alloys, titanium alloys and stainless steel alloys. Support of direct interface to SenteSoftware Ltd JMatPro as well as the possibility to integrate proprietary end-user tabulated data. Multi-material analysis can be carried out thanks to a unique meshing capability allowing defining multi-body within a unique mesh.
  • Anisotropic models as well as complex hardening like kinematic hardening
  • Multiple friction laws are included, Coulomb, Tresca, Viscoplastic and non-uniformed friction coefficients can easily be set.
  • Heat transfer coefficients are available for various ambient media conditions and contact conditions with the dies and non-uniformed HTC can be defined.
  • Multiple damage criteria are available: Latham&Cockroft, Lemaître, Oyane, Shark skin, Rice Tracey…
  • Recrystallization laws are integrated based on macroscopic models that can predict dynamic recrystallization, static/post-dynamic recrystallization, grain growth. Data for these models are available for Nickel super alloys, stainless steels.
  • Customer own models can also be defined as user subroutines.
Prediction of average grain size (ASTM) during the hammer forging of a nickel based alloy aerospace disk. Most recrystallization occurs as meta-dynamic recrystallization in between blows.

 

Part-dies coupled analysis

Predicting accurately the temperature is one of the challenges when designing an aerospace component. With FORGE NxT® multi-body analysis capability, fully coupled thermo-mechanical computation between the component and the dies can be run, offering the highest result accuracy.

Grain size distribution prediction in an Inconel 718 aerospace disk

 

"The analysis carried out with FORGE® to model the evolution of defects in Aeroengine disk forging would not have yielded results this close to experimental values on many other metal forging software products. FORGE® has a unique multi-body approach to modeling such complicated phenomena which enhances the simulation capabilities of processes."

Rajiv Shivpuri
Manufacturing Research Group
Ohio State University
Columbus OH, USA

 

 

Specific equipment kinematic database

Integrated within FORGE NxT® is an extensive kinematic database covering the aerospace’s requirements:

  • Counter blow hammer with multi blows capabilities in a single simulation including waiting time
  • Screw press
  • Hydraulic press
  • Equipment stiffness taken into account
  • Ring rolling mills including radial axial piloting and centering rolls

 

 

Unmatched CPU time reduction

Accuracy of the results is linked with the size of the Finite Element mesh. As market leader in parallel computation, FORGE® NxT brings a unique HPC solution. Large size mesh computations can be run on multi-core machines, with thermo-mechanical resolution, remeshing and mapping being handled fully in parallel. FORGE® NxT offers the highest scalability allowing accurate results within short computation time.

Finisher of an aerospace blade. Hydrostatic pressure is represented.

Final mesh of a Titanium alloy blade consisting of 1 030 000 elements.

 

 

 

 

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