•The program is designed for numerical simulation by finite element method of metal forming processes •The technological process is considered as the operations chain, between which the workpiece and tools can be passed with the inheritance of all calculated fields •The following types of problems are solved: 3D problem, 2D axisymmetric problem, 2D plane problem •It is possible to calculate an operations chain that starts with 2D problems and ends with 3D problems In this case, a 2D workpiece inherited from a 2D axisymmetric or 2D plane problem is converted with all calculated fields into a 3D workpiece
Simulated processes: •Deformation of the material in cold, warm and hot states •Bulk forging on hammers, mechanical, hydraulic and screw presses •Deformation with spring loaded tool or load holder •Deformation processes with a complex tool movement •Open die forging: cogging, section forging, mandrel forging •Radial forging, rotary swagging and rotary forging •Cross wedge rolling •Longitudinal rolling: a separate module that implements automatic connection of the necessary boundary conditions, automatic adaptation of the workpiece mesh and tool in the contact zone, anisotropic friction conditions in the longitudinal and transverse rolling directions, as well as other specialized calculation and interface capabilities •Reverse rolling: a stand-alone module that, in addition to the capabilities of the longitudinal rolling module, has special interface capabilities for the simulation of reverse rolling processes •Cross rolling and cross-roll piercing: a separate module that implements an automatic connection of the necessary boundary conditions, automatic adaptation of the workpiece mesh and tool in the contact zone, as well as other specialized calculation and interface capabilities •Orbital forging and processes with tool rotation around two axes simultaneously •Ring rolling: a separate module that uses special algorithms for simulation and generating a finite element mesh. Complex kinematics of several types of ring rolling mills is implemented in the module. The ring rolling module interface is designed for setting directly those initial data that are entered by the operator of the ring rolling equipment •Wheel rolling •Flow forming •Drawing •Conform processes •General forming of powder and porous materials •Extrusion •Simulation of the rotation of a workpieces or tool in a 2D task •High pressure Forging (hydro forming) •Forging of several workpieces from different materials at the same time •Bulk forming of sheet material •Flash cutting and workpiece piercing •Gravitational positioning of the workpiece in the tool •Cooling and heating of the workpiece in some environment or in the tool •Cyclic tool heating - simulation of the tool temperature as a result of repeated repetition of the same operation •Simulation of phase transformation during heat treatment of steels, titanium, nickel and aluminum alloys. Prediction of mechanical properties of a part after the heat treatment processes •Simulation of diffusion processes •Simulation of grain size evolution according to the JMAK model, with a solver based on the Rado implicit method. The module allows to simulate static, dynamic, metadynamic recrystallization, simulation of grain growth and coarsening of microstructure, and simulation of abnormal grain growth. The effect of temperature on the coefficients of the modelis taken into account, softening due to recrystallization is taken into account, and cyclic recrystallization is calculated •Simulation of induction heating
Advanced simulation options: •Simulation of coupled thermal and mechanical tasks of Workpiece‑ Tool •Prediction of forging defects such as die cavity underfilling, lap, flow-through defects, and suck-in defects. •Simulation of workpiece damage •Abrasive tool wear simulation •Tool fatigue simulation •Simulation of the user subroutines written in the Lua language. It is possible to debug subroutines with the Zero Brane Studio environment. •Standard subroutines calculation for the workpieces: temperature analysis, material flow surface analysis, pressure, flow limit diagram (FLD), damage, element size, stress tensor, strain tensor, thickness, cylindrical coordinate system, etc. •Standard subroutines calculation for tool: pressure, wear, element size, strain tensor, stress tensor, fatigue, etc. •Simulation of viscoplastic or elastic-plastic deformation of the workpieces •Simulation of thermo-elastic-plastic task when cooling or heating the workpieces •Use of symmetry planes, including rotational symmetry •Simulation of assembled tool indicating the values of shrink fittings or fitting with clearance •Boundary conditions set up for the workpieces (velocity, load, pressure, pusher, forging manipulator, rotation, heat rate, etc.) and tools (rigid fixing, support, load, pressure, etc.) •Setting local friction conditions •Setting local conditions of heat exchange with the environment •Setting conditions for spray cooling or heating with gas burners •Setting various stop conditions for the solver: by the displacement and position of the tools, by time, by load, by the value of the calculated fields •Consideration of the orthotropy of the mechanical properties of the material in the simulation process •Simulation of self-contact of a deformable workpieces and the possibility of specifying friction on the surface of self-contact |
•The solver works separately from the preparation of the initial data and the output of the simulation results •The program uses Finite Element Method. For the simulation of the thermal task finite volume method ( Voronoi cells method) is used. •Quadratic triangles in 3D simulation or quadratic one-dimensional elements in 2D simulation are used to describe the tool surface •Linear finite elements are used for the simulation of the workpieces and tool: tetrahedral elements in 3D simulation or triangles in 2D simulation •In the process of simulation, automatic remeshing of the workpiece mesh is applied, while the adaptation of the workpiece mesh is selected based on its own curvature of its surface, as well as the adaptation of the contacting tool surface with the workpiece. •It is possible to introduce additional adaptation parameters for the workpiece mesh: adaptation by temperature and strain, setting the adaptation factor and maximum adaptation factor, specifying the minimum and maximum dimensions of elements of the finite element mesh •It is possible to set local parameters for the workpiece mesh and tools adaptation •The choice of the optimal time step in the simulation process is performed auto by default •It is possible to limit the maximum step and set a constant time step •It is possible to change the norms of convergence of the solution and the maximum amount of iterations per step •The simulation results File contains the results of all simulation steps, which allows you to point and line tracing, as well as the calculation of user subroutines in the Postprocessor mode •It is possible to use explicit or implicit integration method •It is possible to use simultaneously dual mesh method for deformable workpiece: calculation mesh and geometric mesh. This method can significantly reduce the simulation time when simulating some specific processes. Based on the calculation mesh the system of plastic flow equations is solved. The Geometric mesh contains calculated info about thermomechanical fields obtained during the simulation process and describes the geometry of the deformable body. For each mesh , adaptation parameters are set separately. •Efficient parallelization of the process of solving of systems of equations when using multi-core processors •It is possible to use a hexahedral mesh for the workpieces created directly in the program parametrically, imported from other applications, or created on the basis of an imported flat mesh of quadrilateral elements •It is possible to simplify the reconstruction of the hexahedral mesh of the workpieces during the simulation process by dividing the original elements or combining previously repartitioned elements in accordance with the required adaptation |
•Standard Deformed materials database, supplied with the program, contains more than 300 models of steels and other alloys for simulation cold and hot general forming •Alloy Name of the deformable and tool materials can be displayed in standards GOST/TU (Russia), DIN (Germany), AISI/SAE (USA), BS (UK), GB (China), JIS (Japan) •The model of the deformable material may contain flow stress, thermophysical and elastic characteristics, chemical composition, phase transformation models and thermophysical properties corresponding to different phases, parameters of grain size evolution model, parameters of diffusion transformations, damage parameters, electromagnetic properties •The Flow stress of a material may depends on three parameters: strain, strain rate, and temperature. •The Flow stress of the material can be specified in a table view, by the Hensel-Spittel formula, or by a function, described in the Lua user subroutine •It is possible to automatically approximate the experimental data of testing a deformable specimen and determine the coefficients of the Hensel-Spittel formula •The deformable material model can simultaneously contain the parameters of ten well-known damage models implemented in the program •The deformable material model may contain parameters of the JMAK grain size evolution model •Deformable material model may contain thermophysical characteristics corresponding to different phases, as well as parameters of phase transformation models implemented in the program •It is possible to import and export tabular data with extensions *.csv, *.xlsx, *.xls •In the database of deformed materials , it is possible to find for materials by name, chemical composition or parameters values •The standard tool materials database, supplied with the program, contains the most commonly used tool steels •Tool materials models contain mechanical and thermal characteristics, parameters of the fatigue resistance model •The standard Lubricant database contains friction characteristics for some lubricants under conditions of hot and cold forming of steels and other alloys •The lubricants model contains the parameters of the selected friction and the heat transfer parameters. In the lubricants parameters , it is possible to assign sticking and assign non-separable workpiece nodes from the surface of a tool or workpieces in contact with it •One of five standard friction models can be specified in the lubricants parameters : Siebel, Levanov, Coulomb, Mixed or Sticking •It is possible to assign the friction Law with a subroutine •Standard Equipment database contains some hammers models, as well as mechanical, hydraulic, and screw presses •The hammer model allows you to describe gravity hammer , double actions hammer and counter-blow hammer •Two models of hydraulic press are used: direct or accumulative drive •The mechanical drive model describes the kinematics of the crank press. It is possible to set a table of a cyclogram of a mechanical press •It is possible to set a load holder •The universal drive model, helps to describe the complex rotation movement of a tool simultaneously around two axes with a constant or variable velocity or as a result of torque actions on it, as well as the translation movement of a tool with a constant or variable velocity or as a result of a load actions on it. It is possible to specify an axis as the direction of the tool's translation movement. It is possible to set the periodic movement of the tool along a fixed or rotating axes •Table drive type: it is possible to specify the translation movement of the tool by the dependences of displacement on time, or velocity on displacement, or velocity on the distance of the tool to the final position •A list of fixed drives operating along axes OX, OY or OZ is available in the standard equipment database •A list of free drives is available in the standard equipment database , which can freely move along the OX, OY or OZ axes as a result of the actions of a workpieces or other tool on them •It is possible to create simulation parameters database for special processes •It is possible to create Environment Database •It is possible to import data from the JMatPro software with a text file with the extension *.qdat for the deformation simulation and phase transformation simulation •It is possible to export data to a text file with the extension *.qdat (for databases of deformed materials and tool materials)or to a file with the extension *.qdat-bin (for all databases) •Process templates database contains a set of templates with parameters of various technological processes •In the database of ring rolling mills, the parameters of the machines used in the Ring rolling module are set •Sprayers database sets sprayers parameters •It is possible to use a network database, which is located on another computer on the local network •Ability to copy values in selected cells MS Excel and inserting them into a database value table |
•The input geometry for 2D simulation has the extension *.crs or *.dxf and contains one or more closed loops •Input geometry for 2D simulation can be imported directly from files *.dxfprepared in CAD systems •2D geometry prepared in CAD systems can be imported into the 2D geometry editor QDraft from files *.dxf or *.igs and saved to a file with the extension *.crs or *.dxf •2D geometry can be created in a graphics editor QDraft and saved to a file with the extension *.crs or *.dxf •The input geometry for 3D simulation has the extension *.shl or *.qshapes and contains one or more 3D solids whose plain surface consists of triangular finite elements •3D geometry prepared in CAD systems can be imported into the 3D geometry editor QShape from files *.step or *.igs and saved to a file with the extension *.shlor *.qshapes •3D geometry prepared in CAD systems can be imported into QForm UK directly from files with extension *.step •The 3D geometry of some simple bodies can be created in the 3D geometry editor QShape •3D geometry can be created in the editor QShape by rotation or pulling 2D contours imported from files with the *.dxf extension. •3D geometry of some simple solids can be created directly in QForm UK •It is possible to set several symmetry planes in the 3D geometry editor QShape or directly in QForm UK •It is possible to set rotational symmetry in the 3D geometry editor QShape •It is possible to expand or mirror objects over symmetry plane before running the simulation •It is possible to calculate the axes of bodies of rotation in the 3D geometry editor QShape or directly in QForm UK •It is possible to set simultaneously two axes of rotation for a tool in the 3D geometry editor QShape or directly in QForm UK •Preliminary positioning of objects can be carried out as in the 3D geometry editor QShape, and directly in QForm UK •It is possible to import assemblies while saving the position of all objects user defined in the CAD system •Diagnostic and automatic correction of imported geometry is possible •The Amount of geometric objects loaded for simulation is unlimited •It is possible to import finite element mesh with calculated fields from files with the extensions *.ntl, *.pda,*.unv, *.nas, *.nastran •It is possible to change the dimension of the mesh imported from files with the extensions *.ntl, *.unv •It is possible to import a hexahedral mesh or 2D mesh of quadrangular elements from file with the extension *.unv •Scaling, copying and replacing geometry is possible •Export of the original geometric file is possible |
•Viewing of all results is possible both in the Postprocessor mode, and directly in the process of simulation •Displaying of calculated fields is possible separately in the workpiece, separately in the tools, simultaneously in the workpiece and tools •Fields of calculated values can be displayed as a gradient or discrete fringe plot, isolines, isolines with symbols. It is possible to replace the color scale with a scale with grayscale, it is possible to use a custom color scale •The Scale range can be set auto according to the calculated step or operation, by cross section , or manual. The Amount of divisions and the scale step can be adjusted by the user •It is possible to enable the display of marks with the maximum and minimum values on the calculated field •View cube allows you to quickly set the desired view •Simulation objects can be freely moved and rotated in the results view window •Scaling tools available: zoom in frame, zoom out out, zoom in window •It is possible to assign user's colors for simulation objects •It is possible to create arbitrary cross cut plane or section of objects •It is possible to create several sections, as well as an array of sections •It is possible to output the function value at an arbitrary point •The place and shape of the folds are indicated by red dots. •Power contact nodes or workpieces domains can be highlighted in blue color •It is possible to view statistical info about calculated fields •It is possible to export to files with extension *.csv, *.xlsx, *.xls statistical info about the selected calculation field, including the minimum and maximum values of the fields on each simulation record •In the Postprocessor mode inpossible direct and reverse tracing individual Lagrangian lines, an array of Lagrangian lines, an array of near-surface Lagrangian lines superimposed on the workpiece •In 2D simulation in the Postprocessor mode inforward and backward tracing is possible of one or more contours superimposed on the workpiece •In the Postprocessor modeinForward and backward tracing of individual points or an array of points superimposed on a workpiece or tool is possible •It is possible to display graphs of calculated fields values for selected tracking points and export trace results to files with extensions *.csv, *.xlsx, *.xls •It is possible to import graphs with experimental values from files with extensions *.csv, *.xlsx, *.xls and superimposing them on the calculated graphs •Object snap of individual tracking points or individual Lagrangian lines to mesh nodes is possible •It is possible to show graphs of load, work, energy, power, velocity, displacement, moments, and other functions depending on time or other parameters. Graphs can be exported tofiles with extension *.csv, *.xlsx, *.xls •It is possible to display graphs of the values of the calculated distributions along the line in the volume or on the surface of the body •Possibility to saving Images or a series of images with results into a file or a series of files with the extension *.png •It is possible to saving simulation animation to a file with the extension *.wmv with the calculated fields scale on or off •It is possible to saving animation with a frame duration proportional to the value of the calculated step •When saving images or animations of the simulated process, it is additionally possible to record a graphs window, a statistics window, a flow limit diagram window (FLD) and individual parameters: process time, simulation step and simulation number and other useful info. It is possible to set the dimensions of the recorded image •3D display of 2D objects and full display of 3D objects are possible if only their symmetrical fragments with specified symmetry planes are used in the simulation •It is possible to hide and show selected objects, enable transparency mode, enable and disable edge highlighting •It is possible to display a displaced contour or a displaced plain surface of a deformed tool, respectively, in 2D or 3D simulation at different linear scale •It is possible to display on a different linear scale the color vectors of the flow velocities of the deformable material and the vectors of the elastic-plastic displacement of the surface nodes of the tool •It is possible to measure the distance between two arbitrary points, determine of horizontal and vertical dimensions of objects in 2D simulation, and arbitrary sections of objects in 3D simulation •Object snap to mesh nodes is possible when measuring distances •It is possible to display the final distance between two tools during the simulation when the Distance between tools stop condition is assigned •An arbitrary cross cut plane of objects after 3D simulation can be exported to a file with the *.dxf extension •The Geometry of deformed objects after 2D simulation, including flow lines and point, can be exported to a file with the *.dxf extension •Export of coordinates of nodal points of objects contours in 2D simulation or section contours in 3D simulation in *.xlsx or *.xls-files •The Geometry of deformed objects after 3D simulation can be exported to a file with the *.stl extension •It is possible to export a finite element mesh after 3D simulation to files with the *.unv (IDEAS universal file), *.ntl (PATRAN neutral file) extensions •It is possible to export flow lines from a 3D simulation to a file with the *.IGES extension •It is possible to import and export the blows table with the *.xlsx and *.xls files •It is possible to export and import deformed and compensated tool geometry with the *.qmesh extension file •It is possible to export and import objects with temperature and accumulated strain distributions with the *.qmesh extension •Automatic generation of reports of simulation results based on templates is possible in MS Word with the *.dotx extension or templates MS PowerPoint with the *.potx extension •It is possible to export simulation results to the format *.wrl, which can be used for color 3D print or *.3mf •Multi-window mode for viewing simulation results: it is possible to divide the software window into several windows (from one to four), in each of which the same simulated operation or different operation from the same or other projects can be opened (*.qform-files). It is possible to simultaneously synchronize the options for displaying objects and calculated fields in different windows. It is possible to link the position and scale of objects in the different windows (multi-window view) •It is possible to move objects in the applications window with a 3D manipulator •Three scene rotation mode: free rotation mode, mode with the fixed axis, free rotation with partially fixed axis •Right mouse button helps to create a domain of boundary conditions and adaptation, manage objects display options, quickly show graphs for selected objects, set domains with fields values at selected points, and other features •It is possible to adjust the simulation log information in the software parameters •Multilingual software interface |
•Task Manager sequentially launches task for simulation from a list created by the user •Client-server version allows you to use your own server. The data exchange is carried out through a local network. As well as to carry out calculations in the cloud, using the calculation capacity of the cloud server. Data exchange is carried out through a global network in this case •It is possible to save selected processes or operations chains in a separate project •Multitasking: it is possible to run several simulations simultaneously on one computer •Multiprocessing: parallelization of the simulation when using multi-core processors. It is possible to select the number of logical processors simultaneously involved in solving a system of equations and other tasks •Multivariant Analysis: setting multiple values for one or more input data parameters and sequential simulation of variants corresponding to all combinations of variable parameters •API (Application Programming Interface) - it is possible to use user's applications written in languagesC#, Python, VB.Net, VBA, matlab, S-expressions, XML, to manage the simulation and query simulation results. Application Wizard allows you to quickly create code fragments necessary for the work with QForm UK, in any of the listed programming languages without using the documentation |