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Tool Life

Predict the breakdown of forming tool coatings and lubricants over multiple production cycles

In a sheet metal forming process, lubricants or hard coatings are applied on the tool surfaces for the purpose of friction reduction. Friction coefficient is not a constant value during a metal forming process under multi-cycle loading conditions, due to the degradation of lubricants or hard coatings.

The functional module 'Tool-Life' is developed by using a unique interactive friction modelling technique Read More to prdict the evolutions of fricton coefficient and the breakdown of the lubrication or hard coatings, under multi-cycle loading conditions.

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Tool Maker

Design forming tools to realise your target post-form component properties

For a warm/hot stamping process,two key issues may be concerned by toll designers. - Dimensional accuracy - Quenching efficiency,which is tool material and surface condition dependent. The functional module 'Tool-maker' is a unique tool to evaluate the quenching efficiency of different die materials during warm/hot stamping processes.

Tool-maker is offering tool design guidelines for different combinations of tool and workpiece materials.

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IHTC Mate

Determine IHTC value accurately during forming

The interfacial heat transfer coefficient (IHTC) is a key parameter in a warm/hot stamping process to determine the post-form strength of pressings. IHTC values are highly sensetive to tool materials and surface conditions.

The functional module 'IHTC-Mate' is dedicated testing equipment integrated with Gleeble to determine the IHTC values between different tool and workpiece materials at various surface conditions.

Data provided by the 'IHTC-Mate' include the IHTC values between commonly used die steels, cast iron and aluminium alloys in development.

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Tailor

Build a customised forming process with flexibility, using optimised forming conditions, to accurately predict post-form

The hot stamping of aluminium alloys is a tailored forming process, with the assigned processing windows determining the quality of each hot stamped component in terms of its post-form strength. Tailor can define the optimal processing parameters that should be used in a production line to successfully produce a component with the desired post-form strength using hot stamping. 'Tailor' was developed using the results of forming tests, air cooling tests and multi-stage artificial ageing tests, which provided guidance on the value for the die closing force, transfer time and artificial ageing time to be used in the hot stamping process.

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Strategy

Create a material test matrix based on accumulated data on forming processes

Reliability of the FE simulation of a metal forming process relies on the accuracy of inputs. Material testing plans are usually made according to experience. 'Strategy' is offering material testing guidelines obtained from an innovative data-driven approach, allowing sophisticated material testing plans to be made towards a specified metal forming process.

'Strategy' is offering guidelines for uniaxial tensile tests to determine the flow stress of a workpiece material.

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Fitting

Fit developed numericla models to your material test data

The composition and processing of metals will strongly affect the mechanical and deformation behavior of the material. Therefore, it is essential to ensure that the material parameters used in modelling are accurate.

However, this is not trivial, At SmartForming, we provide an automated process to find the material parameters for a number of commonly used material models, using a variety of optimization algorithms. The process is fully automated and the user only has to input the experimental results and select the relevant models, which facilitates users as they no longer need to write codes to perform such calculations.

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Uni Form

Physically simulate an optimised and customisable production line remotely

Uni-Form is such a dedicated pilot production line, which enables the processing parameters generated in Tailor be realised and verified through the automated, high accuracy production trials. It consists of four main sub-systems: the furnace, forming tools, conveyor and incubation chamber to duplicated the heating, forming and heat treatment processes involved in sheet metal forming. Equipped with a powerful conductive heating facility, a maximum temperature of 600°C and a fast heating rate up to 100°C/s could be implemented. Also, the position accuracy of the conveyor system can achieve as high as 0.5mm.

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Formability

Predict forming limit of formed part under warm/hot stamping conditions

An intrinsic feature of the hot stamping process, in which a hot blank is quenched and formed between water cooled dies, is the severe thermo-mechanical deformation that the blank experiences under the combined influences of non-isothermal and non-proportional loadings. This results in challenges for conventional forming limit prediction models to accurately predict material behaviour. Formability module offers a novel viscoplastic-Hosford-MK model to predict the forming limits of material under warm/hot stamping conditions and finally optimise the forming parameters.

The functional module ‘Formability’ is developed using a unique The Viscoplastic-Horsford-MK model Read More to predict failure of warm/hot-stamped part.

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