Improving Quality and Lifetime of Forged Products with Process Simulation

This guest contribution on Innovation Intelligence is written by Adhish Majumdar, Research Engineer at GeonX, and Laurent D’Alvise, CEO & Founder at Geonx. Virfac® by GeonX is a tool used to simulate welding, additive manufacturing, machining, heat treatment and damage resistance and is available through the Altair Partner Alliance.

There are several techniques used to perform surface hardening on large steel parts, the most popular of which is induction hardening. Induction hardening is a very quick process that allows precise control of the hardening depth and leaves the surface clean and smooth. Simulating this process ahead of time helps overcome several challenges and saves time and money during the production process. A couple of these challenges include unexpected hardening depths due to an improper temperature profile and distortions and residual stress “hot spots” which can both lead to an increased number of trials before production. Virfac®- Virtual Factory developed by GeonX, makes it possible to easily setup and simulate the entire manufacturing chain in order to optimize the parameters involved in the induction hardening process. This simulation results in higher quality and longer-lasting products.

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