virtual manufacturing made real
TRANSCRIPT
Virtual Manufacturing
made real
Born from 10 years of Research and Development, VIRFAC® aims to provide the customers with a cutting edge product that delivers high quality results within a short span of time to tackle present day challenges in the manufacturing industry.
• REDUCES PRODUCTION COSTS IMMENSELY
• SHORT TIME TO MARKET
• RETURN ON INVESTMENT IS HIGH
• STAGGERED THERMO-MECHANICAL COUPLING
• STAGGERED THERMO-FLUID COUPLING
• MECHANICAL AND THERMAL CONTACT MANAGEMENT
• XFEM AND LEVEL-SET TECHNOLOGIES
• REMESHING CAPABILITIES
• ADAPTIVE, VARIABLE AND FIELD CONTROLLED TIME STEPPING
• EULERIAN, LAGRANGIAN AND UPDATED LAGRANGIAN FORMULATIONS
• CONSTANT, CYCLIC AND PERIODIC DIRICHLET BOUNDARY CONDITIONS
• SPECIFIC MANUFACTURING NEUMANN-TYPE BOUNDARY CONDITIONS
• INNOVATIVE AND EASY TO USE GRAPHICAL USER INTERFACE
• FAST AND PRECISE COMPUTATIONS WITH THE MORFEO SOLVER
1 • Workpiece Geometry
2 • Material Properties
3 • Process Parameters
1 • RESIDUAL DISTORTIONSVirfac® predicts the distortions encountered by the workpiece due to manufacturing and helps you to optimize your processes.
2 • RESIDUAL STRESSESVirfac® predicts the level of residual stresses and helps you to calculate the in-service fatigue life to the manufactured part.
3 • METALLURGY AND QUALITYVirfac® predicts the metallurgy and quality of the manufactured component.
Power of Virfac®
Benefits of Virfac®
Features of Virfac®
SIMPLY PROVIDE VIRFAC® WITH:
PHYSICS FINITE ELEMENT METHOD
BOUNDARY CONDITIONS AND FORMULATIONS
AND VIRFAC® MAKES YOU GAIN:
SURFACE HEAT TREATMENT OF A FORGED CRANKSHAFT
• This is a chained process which includes, surface heating by induction followed by a hold phase and water quenching that is simulated with Virfac® Heat Treatment module.
• Based on a staggered coupling between thermal-metallurgical-mechanical calculations, the simulation leads to the prediction of the phase transformation in the workpiece in addition to the residual stress mapping and the thermal cycle.
• The setup and computation take less than 24 hours thanks to respectively the friendly user interface of Virfac® and its massively parallel computation capabilities.
• Virfac® results are validated following a comparison with literature.
Typical residual stress profile after induction hardening
Virfac® residual stress profile after induction hardening
VIRFAC® HEAT TREATMENT
more about Virfac®
INFLUENCE OF WELDING SEQUENCE IN A MULTI-WELD OPERATION
STUDY MADE FOR STELIA-AEROSPACE ABOUT STRUCTURAL BEAM OF THE MAIN LANDING GEAR BAY A350
• The Virfac® Welding Scheduler is a key module for the Inherent Strain Method (local-global approach) and in optimizing welding sequences (when a number of welds needs to be performed) which produce the lowest distortions, and therefore it is considered as one of the most competent tool for the engineers in the planning stage of the product.
• The example above illustrates the capability of the Welding Scheduler. By changing the welding sequence it can be seen that the overall distortion is reduced. Therefore by utilizing an efficient welding sequence the residual distortions in the part can be decreased.
• The added advantage of the Welding Scheduler is that it not only cuts down the work for the engineer but also does it at an extremely quick pace.
• The chaining of a multi-step machining operation of a complex aeronautic structure is easily modeled with Virfac® Machining Direct module. Every linear-elastic computation of a step is based on the results of the previous one as initial conditions.
• This simulation is validated by a comparison between the Virfac® results and an experimental measurement done on the real workpiece as shown in the following graph.
• Virfac® Machining modules lets the manufacturing engineers check the effect of the clamping system and the machining sequence on distortion.
Machining Sequence 1
Y-Stress mapping with the clamping system
Y-Stress mapping after the removal of the clamping system
Machining Sequence 2 Machining Sequence 3 Machining Sequence 4
VIRFAC® WELDING SCHEDULER
VIRFAC® MACHINING DIRECT
Virfac® Products matrix
WELDING SCHEDULER
WELDING MEGA
ADDITIVE MANUFACTURING
CRACK PROPAGATION
WELDING DESIGNER
MACHINING
HEAT TREATMENT & CARBURIZING
FRICTION STIR WELDING
Fully transient & highly accurate thermal-
mechanical-metallurgical simulation of welding
process suited for post welding damage analysis.
Fast methodology for computation of residual distortions in small and
large components.
Built on XFEM technologies and highly
flexible prediction of crack generation.
This module is based on thermo-fluid
formulations & can be utilized for particle flow
calculations.
Advanced slicing features coupled with thermo-mechanical-
metallurgical analysis.
Time efficient optimized computation of
distortions for long & high number of welds.
Time efficient computation of massive
sheet metals with an embedded weld
database.
An effective heat treatment module combined with
extremely quick estimations of carbon diffusion into
workpiece.
GEONX DEVELOPS ROBUST AND POWERFUL SOFTWARE PACKAGES
TO SUPPORT MANUFACTURING ENGINEERS IN THEIR DAILY DESIGN DUTIES.
FROM THE DESIGN OFFICE TO THE FACTORY, VIRFAC® (VLRTUAL FACTORY), PROVIDES
AN ACCURATE, POWERFUL AND INDUSTRIAL PLATFORM FOR VIRTUAL MANUFACTURING.
MAKING VIRTUAL MANUFACTURING A REALITY IS THE MISSION OF GEONX.
GEONX AROUND THE WORLD
ADDITIVE MANUFACTURING
WWW.GEONX.COM
7a, Rue Santos Dumont, 6041 Gosselies, Belgium
Mail: [email protected]
“ GeonX has always excelled in pushing the boundaries of Virtual Manufacturing, in a wide variety of fields ranging from Welding, Machining & Heat treatment to Additive Manufacturing & Damage investigations in order to bridge the gap between the real world and virtual world.”
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CONTACT US FOLLOW US
OUR CLIENTS’ SECTORS
Aerospace
Automotive
Rail industry
Naval and Heavy
Engineering Services
Energy
Robotics and Machinery
Other
OUR CLIENTS WORLDWIDE
North America
Latin America
Western Europe
Eastern Europe
Scandinavia
North Africa
Eastern Asia
Western Asia
Southern Asia
BELGIUM
GEONX S.A. (Headquarters)
Aéropole de GosseliesRue Santos Dumont 7A 6041 Gosselies - Belgium
CHINA
IUIT Group Ltd.
Room 805, Diyang Tower Xin No. 2Chaoyang District Beijing - China
Tel.: 86 10-84470288-818 www.iuitgroup.com
JAPAN
JSOL Corporation
Harumi Center Building, 2-5-24Tokyo-104-0053Japan
FRANCE
GEONX FRANCE SAS
68 Avenue Jean Jaures33150 - BordeauxFrance
EASTERN EUROPE
FEA Projects
Brzozowa 14 Street, 05-119, Łajski, Poland
Mobile: +48 502 526 [email protected]
SOUTH KOREA
Korea Simulation Technology Co.,Ltd
Rm.804 Nam-Jung City Plaza 1th,760 Janhang-dong, Ilsandong-gu, Goyang-si, Gyeonggi-do,410-380, South Korea