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Manufacturing process simulation

For a long time, aviation enterprises mainly rely on experience and test for process improvement, and lack a set of professional and effective methods and means. With the rapid development of computer technology and CAE technology, process simulation has gradually become the best solution to control the design and manufacturing process and predict the possible problems in the early service of products in the international advanced aviation enterprises. In the process of workpiece from design to processing, the traditional manufacturing method based on experience and repeated physical test verification is far from meeting the needs of rapidly adapting to market changes and enhancing market competitiveness. In fact, the process simulation is like a numerical laboratory that completes the molding test on the computer, checks the feasibility of the product processing process and the quality of the processed product. A lot of information can be obtained from each numerical experiment, after analysis, the factors that affect the quality of the product can be found, after one by one modification, repeated trial calculation, and finally can optimize the best process, process parameters and material parameters of the molded product. After completing many numerical simulation experiments with the help of process simulation software, the technologist can also accumulate rich technical experience and improve the technical level.

Solution

Hexcon has several CAE softwares suitable for simulation of various machining processes, such as Marc,Simufact, Digimat, etc. Marc is the world's first advanced commercial nonlinear finite element software, which has the super ability to deal with large deformation geometric nonlinearity, material nonlinearity, boundary condition nonlinearity including contact, and combined high nonlinearity. It has high numerical stability, high precision and fast convergence of highly nonlinear problem solving technology. Marc's excellent grid adaptive technology not only ensures the calculation accuracy, but also greatly improves the calculation efficiency of nonlinear analysis; marc's parallel finite element algorithm based on the domain decomposition method can maximize parallelization in the finite element analysis process, and the parallel efficiency can reach quasi-linear or even linear or superlinear. Marc can be used for various types of machining process simulation, such as sheet forming, bulk forming, blowing, welding, powder metallurgy forming, heat treatment, CNC machining, cutting, and cutting.

Simufact.forming is a professional process simulation software mainly used for metal plastic forming, welding, mechanical connection and heat treatment simulation analysis. The main process types that can be simulated can be divided: cold and hot heading, cold and hot forging, cold and hot extrusion, drawing, open die forging, closed die forging, sheet metal forming (stamping, deep drawing, embossing, bending, flanging, punching, etc.), spinning, rolling, billet forging (free forging, mandrel drawing, radial forging, horse bar reaming, etc.), plate rolling, wire rolling, profile rolling, pipe rolling, vertical ring rolling, horizontal ring rolling, heat treatment (, tempering, annealing, quenching, induction heating, induction hardening, etc.), mechanical connection, friction welding, resistance spot welding, mold stress analysis, etc. Simufact. According to the classification of forming processes, the forming is divided into cold forming, hot forging, sheet metal forming, rolling, ring rolling, free forging (billet forging), heat treatment, mechanical connection, pressure welding and general purpose, which is convenient for users to select processes according to their own process types. The software recommends corresponding default parameters, solver settings and solving incremental steps according to different process types, I .e. there is no need to deeply understand the theory of finite element, you can use the software for analysis, easier to use.

Simufact.welding is a professional welding simulation software, which can simulate and analyze the welding process of complex structures and assemblies, analyze and predict the maximum temperature and heat-affected zone of the temperature field, and accurately predict welding deformation and residual stress, so as to help users find problems in the process scheme and formulate appropriate improvement strategies to minimize the degree of deformation and residual stress, so as to achieve the goal of guiding the optimization design of welding process. Simufact. The welding can assist in exploring the optimal tooling design based on the use of real tooling geometry; at the same time, the clamping force is also included in the scope of investigation. By using Simufact.welding, we can analyze and compare the influence of different welding sequences and other welding processes on welding quality, and finally determine the best welding sequence and other process parameters. Simufact. The welding can assist the user to realize the function of process optimization design and has the function of rapid process replication. After replication, the process personnel can modify the process according to the actual process plan, including tooling and fixture, welding sequence, welding parameters, etc. After submitting the calculation, the results of different process schemes can be compared in the same interface, which helps the process personnel to select the appropriate process conditions and select the optimized process parameters. The rapid process replication function greatly saves the modeling time of engineers.

Digimat is a commercial software package focusing on multi-scale nonlinear material constitutive model prediction and material modeling of composite materials. It can simulate/predict the curing warpage deformation law of composite structures. Can establish a multi-scale curing dynamics model; Can consider the influence of manufacturing process parameters (ply direction distribution, etc.) on structural curing; Can predict the curing springback of composite parts based on the curing dynamics model.

Hexcon's manufacturing process simulation program has been widely used internationally and domestically, and has become an indispensable tool for world-renowned companies to develop new products and design new processing technologies.