FORGE®

Keywords

Closed Die Forging
Open Die Forging
Extrusion
Ring Rolling
Cross Wedge Rolling
Reducer Rolling
Friction Stir Welding
Rotational Friction Welding
Heat Treatment
Microstructure

FORGE® is the world leading simulation solution for any bulk material forming deformation. More than 30 years of experience and development have made FORGE® the most reliable and most recognized solution for large material deformation simulation. FORGE® can simulate any manufacturing process for hot, warm, and cold forging, which includes but not limited to:

* Closed die forging

* Open die forging processes such as cogging, saddling, and other GFM processes 

* Rolling for long products

* Extrusion

* Ring Rolling

* Cross Wedge Rolling and Reducer Rolling for pre-forming

* Friction Stir Welding (FSW) and Rotational Friction Welding

FORGE® is also the most advanced solution for Heat Treatment simulation, and Microstructure analysis. Thanks to its unique Finite Element Method (FEM) solvers (Norton-Hoff and Elasto-Visco plastic), FORGE® resolves all equations at the same increment, and can take into consideration any variation of parameters that will impact the global equation system. This is unique, and as a result FORGE® is the most reliable and accurate material forming simulation software.

FORGE® is an all-inclusive software, which comes by default with the complete functional software  set of capabilities including Heat Treatment, Microstructure, Optimization, 2D and 3D and much more.....
There is no need to buy additional modules with FORGE®. To understand the way we license our software, please refer to the Licensing Policy section.

FEM

Technical Papers

Automatic Reports
Custom Templates

TOOL DESIGNER ASSIST

Optimization

FORGE® is the perfect simulation software to assist your design engineers.  With FORGE®, engineers can test, analyze, compare, predictvalidate and optimize the final design before going to production.
The end result? The right design the first time, everytime.

The Tools Stress Analysis is another essential part of FORGE®. It is crucial for design engineers to understand the level of stresses involved in each new design. The final validation of the design will also be influenced by the comparison of the various stress levels in the tools considering that the cost of tooling  is an important item of the total cost.

Materials Database
Materials Generator

Hardware

Recommendations

The Pre-stressed tools are widely used to reduce the amount of stress in the tools during forming. As mentioned above, this is critical to accurately quote a product to a customer, and consequently increase the profit margin of a specific product. FORGE® offers the possibility to compare different pre-stressing options. The information that results allows tool designers to choose the best solution.

The automatic reporting is another key feature of FORGE® and a significant time saving for engineers. Reporting is an under-estimated task that tool engineers have to perform, and most of the time it is not even included in the design schedule. It is a significant workload for tool designers who have to deliver on time with a supported argumentary justifying their design choices to their manager.FORGE® makes reporting easy, fast and painless by providing a customizable automatic reporting system. All design parameters related to parts, tools and equipment are automatically captured into a fully interactive 3D report in a Microsoft Office format. With FORGE® automatic reporting, time and energy is spent where it matters most:  the tool design!

FORGE® works with all classic formats available in any CAD software (STL, STEP, STP, dxf, x_t,...). 

MATERIALS DATABASE

The material definition is the keystone of any simulation. Without accurate material data, there is no accurate simulation result. Transvalor has worked relentlessly since its inception to offer the best material definition information to its customers. It is a 4-prong solution:

* Material Database: FORGE® by default comes with a database of more than 800 Materials characterized specifically for Hot forging and 200+ for cold forming applications. Some of the grades have multiple variations based on their initial state.

* Material Generator for cold forging: Because most of material grades have many initial states from annealing, and other heat treatment, FORGE® offers the possibility to generate your own material for your cold forging operations. Once generated, the material is stored in your personal database, and can be re-used anytime. 

* Materials from JMatPro: JMatPro is a material simulation software from the UK-based company Sente Software. They have designed a well recognized simulation software for the generation of material properties. Transvalor and Sente Software have joined forces, and all material definition files generated with JMatPro are compatible with all our software. It is a great way to avoid the costly expense of material experiments.

* Material Experiments: Transalor has always offered the possibility to generate your own material from experimental data. Any experimental data can be plugged into Transvalor Simulation Solutions.

MOST RELIABLE SOLUTION

Since 1984, Transvalor has repeatedly proven to be the expert in Finite Elements Method (FEM) technologies. Transvalor is born of Research and has maintained a strong association with the Center for Material Forming (CEMEF), a research center of the prestigious MinesParisTech, whose main activities are centered around material forming and numerical computation. This partnership provides a constant flow of advanced scientific developments that translate into innovative new functionalities to Transvalor’s products for the benefit of our customers.

Meshing techniques are the at the center of the Transvalor/CEMEF partnership. Meshing and re-meshing techniques are the make-or-brake of FEM simulations. We believe there is no other vendor to this day able to compete with the technology of our re-meshing algorithms, and their reliability.

What it means for the end user, is the guarantee that the simulation will not crash. Crashes are a waste of time, and bring a degree of frustration to the designer. Our philosophy is that crashes have no place in our solutions. The re-meshing technique is the most common reason for crashes. When the process parameters are entered properly, the simulation should complete without incident. Our expertise in this area makes us the most reliable solution on the market. But do not just trust us, try us!

In addition to our re-meshing technique, our solvers have been crash-proofed for over three decades. Our developers pay particular attention to the quality of their coding to ensure the highest solver quality possible. Our development team continuously works on optimizing the code to decrease the computation time, and remove potential risk of conflict.

Finally, our experience in forging (hot, warm, and cold) for more than 30 years makes Transvalor the most knowledgeable, and reliable partner in FEM simulation solutions. We have worked with your industry long enough to understand your priorities, your challenges. We work for you and with you, to bring you the best simulation solution for your business.

SCALABILITY

Scalability for a simulation solution such as FORGE® is the software ability to use more computational cores in order to reduce the global computation time of the simulation.

 

FORGE® is known to be one of the fastest simulation software on the market at equal number of computational cores, but where FORGE® stands out in a crowd of other simulation software is its ability to efficiently use large number of
cores for simulation calculation.

With multi-processor computers becoming significantly more affordable, larger and larger computing
server configurations are finding their ways into engineering departments. FORGE® will efficiently
scale up to 64 cores with sustained performance gain when cores are added. When others choke at
the 8 processor mark, FORGE® keeps climbing.  FORGE® is the most capable simulation sotware
to fully utilize the new computing capacity available to engineering departments. 

FORGE® offers an un-matched parallel efficiency already and our teams are unyieldingly working to
make it even better. 

But, although using more cores to speed-up simulation computations is generally efficient to improve
computation time, it is not the only solution. Transvalor is also working in other directions like:

- Bi-mesh techniques, Steady states formulations, Multigrid,...

Improving the efficiency of our solvers is an every day concern.

OPTIMIZATION

MICROSTRUCTURE

FRICTION WELDING

OPTIMIZATION

MISCELLANEOUS

Presentations

Optimization is a generic term often misconstrued. It is important to explain what we consider optimization, and what FORGE® has to offer on this topic.

Optimization allows the designer to produce the best design in a given framework. FORGE® optimizer does just that. We use the most advanced genetic algorithm to determine what parameters will be the best fit for what the designer is trying to accomplish. FORGE® "tells" the designer which solution is best, instead of just presenting the results of all solutions, as it is the case with a Design Of Experiments (DOE). The DOE is one feature of the optimization in FORGE®, but the optimization is way more than just the DOE.

A classic example of optimization is the optimization of a tool design. It is un-realistic to run an optimization from scratch, but once the designer has found her or his "best" design, she or he can run it through the optimizer in order to determine if there is still room for improvement, and in most cases, there is!

Our optimization works with all the major CAD vendors (Solidworks, CATIA, Pro-E,...), and any CAD with a script mode. FORGE® optimization modifies the design by communicating back and forth with the CAD software.

You can watch an example of "How to" in our newsletter here.

VIDEOS

Articles

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