Steel Industry

In spite of the strong competition between composite as well as lightweight materials and metals in general, and steel in particular, steel production is still the dominant play-maker through the entire engineering sectors around the globe. In addition, steel and metal industries are deemed to be one of the driving sources for the Gross Domestic Product for every nation.

Steel and metal production can be broken down as semi-finished products which come out of rolling and/or forging of ingots into billets and slabs, and finished products such as reinforced steel rebars, coils and wire rods, beams and sections, fasteners, pressure vessels, pipes, and tanks. In order to meet the client’s design conditions, these products have to follow various specs in terms of yield strength, ultimate tensile strength, modulus of elasticity, strain, fracture toughness, fatigue. Besides, manufacturing processes defects such as casting, rolling, forging, and welding should be addressed well and compensated. For instance, flatness, crown and wedge, edge cracks, roll deflection, lateral deformation, and residual stresses in rolling; porosity, cracks, and segregation of casting; incomplete root fusion, overlap, excessive penetration in welding.

Furthermore, the strict requirements of national and international standards of ASTM standards and codes such as European, Egyptian, American, British codes, force the manufacturers to design their products in compliance with them in terms of Grade, Type and Class to be all on the same page of chemical composition, de-oxidation techniques, strength and surface finish.

However, in order to meet all of the aforementioned specs and catch the surging demands of the 4.0 industrial revolution, development cycles, achieve competitive product cost controlling the three constraints of management; time, cost, and quality, new novel techniques have to be implemented to make the best use of the computational breakthroughs in modeling and speeds to directly control and optimize all these governing parameters.

EOSTrack Manufacturing Solutions

“Simulation helps industries reach their skyrocketing demands using computational manufacturing simulation with drastic reduction of cost, energy, waste with optimal values and free-emissions environment”

                                                                                  -EOSTrack Team

EOSTrack Engineering & Agencies, as a MSC Software Business Partner in Egypt, Saudi Arabia, Kuwait, Bahrain, believes in its pivotal role in the fusion between computational modeling and physical manufacturing facilities as it become a pressing issue nowadays to confront all the fabrication challenges to optimize time, cost and energy being used. Instead of excessive, less accurate, pricey physical trials and error processes being practiced for hundreds of years in steel and metal industry which strongly function of the experience of the workforce that would take years and years to be developed. Not only do these factors drive these practices, but also, it consumes gigantic proportion of production time, need to continuously change the designs. In terms of cost, a 30% uncertainty can lead to 90% of extra direct cost of the needed equipment and 5-9% depending on the materials being using.

EOSTrack help their customers implement simulation technology to get a short cut of all these processes as well as trial to state-of-art Multiphysics solutions that cover the entire manufacturing processes from steel making; casting, forming, welding, additive manufacturing, to high performance, durable and reliable products to be embedded in numerous industries such as construction, automotive, oil & gas, and machinery ones. EOSTrack offer a complete tool chain of simulation tool of MSC ONE with more 70-year experience in the field of simulation and modeling by providing tools, trainings, and consultation for the latest technologies in:

  • Forming

  • Welding

  • Additive manufacturing

  • Multiscale Material Modeling from Nanoscales to Macro scales

  • FEA (Finite Element Analysis) performance testing of products in terms of mechanical and thermal strength

  • CFD (Computational Fluid Dynamics) for modeling heat treatment processes such as quenching, tempering and aging

  • Cost estimation according to the latest market prices

Using all these tools and the experience of expert engineers in the field of manufacturing, material and modeling help industries save billions of dollars annually which will increase the profit margin for both small, medium and huge steel and metal manufacturers.



 
 
 
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• Understand and optimize your manufacturing processes

• Guarantee process feasibility and stability

• Develop new products more efficiently

• Best-in-class usability

• Modular product approach

• Process chain simulation

 


 
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Added value of simulation to metal forming

using Finite Element Analysis:

 

Simufact Forming addresses companies from the manufacturing industries which are specialized in the area of metal forming and joining processes. The software covers materials such as steels and non-ferrous metals, for example carbon steel, high and low alloy steels, stainless steels, aluminum, brass, copper, titanium, nickel base alloys, etc.

Automobile manufacturers and their suppliers, vehicle construction, machinery and plant engineering, aviation and aerospace, electrical industries, energy generating companies, medical devices, and many other industries and branches employ Simufact simulation software in the production planning.

Realistic results, short computational time, ease-of-use

Simufact Forming captivates with its capability, in displaying a unique broad physical spectrum with greatest accuracy in the simulation results (thermal/ materials/ mechanism). At the same time the software convinces with short computational time and with its ease-of-use. Additional items that we address with our simulation software are:

• Increase the efficiency of metal forming- and joining processes

• Find the right process chain depending on manufacturing technique, batch sizes, and existing manufacturing plants

• Shorten process development time (time-to-market-issue)

• Reduce your costs, due to alternative manufacturing processes

• Deepen your knowledge about the manufacturing processes at an early design phase (feasibility)

• Build up valuable knowledge (apart from personnel fluctuation and retirements)

• Meet the quality and performance requirements of your customers’ specifications

Simufact Forming is used as a modern simulation tool in the construction department, method planning or in the process development. In the hands of a manufacturing practitioner or a design engineer Simufact Forming leads to a better understanding of the process. It furthermore helps to reduce the number of expensive and complex tests. Optimized manufacturing processes by an increased product quality, shorter development cycles through a faster process development, faster performed feasibility studies, all this reveal the benefits of process simulation with Simufact Forming.

Ease-of-use for the highest level of productivity

Simufact Forming is a simulation tool for hands-on professionals working with forming technology. The software is aligned to the practical needs of our users. Simufact Forming is practice-oriented, fast and easy to learn. The user can focus on the engineering-related details of the forming process instead of dealing with the software.

Simufact Forming’s practice-oriented and user-friendly user interface allows for the software to be easily used. Therefore, it becomes an engineering tool for designers of dies or processes which supports and simplifies their daily work. With a few clicks, you can simulate and evaluate all standard-forming processes.

Operating advantages of Simufact Forming

• Easy, intuitive user-friendly interface (e.g. drag & drop)

• Very easy and quick to learn

• Metal forming terminology is used

• AFS technology (application function sets) supports the user in creating a simulation whilst:

… Uses a pre-configured simulation model and thereby decreases several adjustments for the user

… Expert settings are made

… Thus the usage of the software is downsized and simplified

• Clear structure according to the object area (dies, machines, material etc.), process area (forming operations) and graphic model / results area

• All commonly used objects which define process characteristics of the simulation model can be stored for later use in the database

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Reach your aim more quickly with

process specific functions

Simufact Forming has a modular architecture. The modular concept helps you to choose exactly the relevant functions for your manufacturing processes. This approach saves you costs and gives you the flexibility to adapt to changing requirements. Therefore, we consciously set ourselves apart from competitor’s products, as they follow the approach to cover all application fields as “general purpose-tool”, but do not offer deeper process specified functions.

The dedicated Application Modules provide you process specific functionalities for all areas of forming processes. They enable for the simulation of single manufacturing steps and can be combined to simulate entire process chains. Additional modules offer you a wide range of further valuable functions for the daily use of the software.

 


 
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  • Identify the optimal process parameters

  • Avoid welding distortions and stresses

  • Find answers to process stability issues

Simufact Welding realistically predicts distortions and residual stresses and helps the user to determine appropriate strategies to minimize them. It is the only simulation software which automatically considers the complex contact situation between the components, which in turn allows conclusions about the properties of the weld seam, in particular its strength, to be drawn. Simufact Welding achieves this by calculating the micro-structural properties within the heat-affected zone, which also gives the user a valuable insight into identifying welding defects, such as hot cracks in the simulation, and how to avoid them in practice.

Simufact Welding assists in finding the optimal clamping devices based on the implementation of real tool geometries, while considering clamping forces and clamping stiffness. Besides the clamping concepts, also the suitable welding sequences can be identified with Simufact Welding. The software predicts the final contour of the work-piece and helps to achieve serial production with minimum tolerances. A new visualization concept ensures that the entire welding process, with all its process steps, can be reviewed immediately, influencing factors can be visualized and different variants are comparable at a single glance.

Simufact Welding does not only consider the heating effects in the welding process, but also includes the ability to create initial welding process simulations e.g. the simulation of resistance spot welding. Even questions which include the parameters to be set up at the welding device and the process stability can be answered.

Also the influences of coatings and point sequences in the process can be analyzed.

Speeding-up the design of optimal welding processes

As a modern simulation tool, Simufact Welding has been designed for use in design departments, method planning, or process development. Simufact Welding in the hands of a welding production expert or of a development engineer not only leads to a better understanding of the processes but also helps reducing the number of expensive and time-consuming trial runs. Optimized production processes with higher product quality, shorter development cycles thanks to a faster process development, faster conducted feasibility studies, these are the advantages of process simulation with Simufact Welding.

Eight reasons why Simufact Welding can innovate your manufacturing

Employ Simufact Welding and …

1. … identify critical distortions, i.e. with respect to assembly, bulging, imbalances, and clearances

2. … investigate and optimize clamping tools even before an investment in tools has been made

3. … identify optimal welding directions and welding sequences

4. … investigate the infl uence of unclamping on welding distortions and residual stresses

5. … gain knowledge about the development of the heat affected zone

6. … use a tool which supports you during planning of welding processes

7. … innovate your process design:

- Virtually test and evaluate different variables without and avoid extremely expensive real tryouts

- Examine the material behavior during the welding process

8. … verify the quality of welding seams, i.e. by calculating nugget sizes, brittle metallurgical phases, hardness, and effects of preheating.

More efficient modelling through improved user-friendliness

Simufact Welding is a simulation tool for hands-on professionals working with welding technology. The software is aligned to the practical needs of our users. Simufact Welding is practice-oriented, fast and easy to learn. The user can focus on the engineering-related details of the welding process instead of dealing with the software. It is possible to do every simulation step from a single user interface: modeling, calculation and evaluation.

The practice-oriented and user-friendly user interface of Simufact Welding enables the ease of use of the software. Therefore, it becomes an engineering tool for processes designers which supports and simplifies their daily work.

The Creation and Assignment Wizards for geometries, materials and marginal boundary conditions allow for a faster and automated assignment of objects to the chosen processes. Wizards (or assistants) are software functions that support the user in data input with the help of dialogues. The wizards help to make data input more ergonomic during the pre-processing for the definition of the welding process. Simufact Welding supports automated process design based on already computed processes as well as the automatic assignment of computation results.

Simufact Welding employs Gantt diagrams to visualize process times. Gantt diagrams visualize the time sequence of process steps as bars on a time axis. With Simufact Welding the former static Gantt diagram becomes an interactive Process Control Center (PCC), which can be used to optimize welding sequences, cooling and clamping and release times. Within the PCC, the visualized tools and robots can be faded in and out, grouped, or sorted as required. The PCC also provides functions to compare and export results allowing for the optimal documentation of process variants.

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Reach your aim more quickly with process specific functions

Simufact Welding has a modular architecture. The modular concept helps you choose the relevant functions that most exactly fit to your manufacturing processes. Simufact Welding consciously sets apart from competitor’s products by offering deeper process specified functions, rather than following the approach of having ‘general-purpose-tools’ that cover all functions.

The dedicated Application Modules provide you process specific functionalities for all areas of welding processes. The modules allow for the simulation of single manufacturing steps and can be combined to simulate entire process chains. Additional modules offer you a wide range of further valuable functions for the daily use of the software.

 


 
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Simufact Additive is a process solution to get parts first time right.

Distortion of parts during the printing and manufacturing process is a major impediment to companies that want to realize the full benefits of the additive manufacturing process. An enormous amount of unproductive time and cost is spent on trial and error. Simufact Additive is a solution aimed at predicting and resolving distortion and failures during the entire print, heat treatment, cutting and HIP process - before producing a real part on the machine.

Typical challenges in Metal Additive Manufacturing

Challenges from a business point of view:

• High hourly machine costs (due to machine acquisition and power costs)

• Machine availability: Experimental testing on the machines reduces the productiveness

• Relatively high material costs

Challenges from a technical point of view:

There are various influencing factors in the additive manufacturing process with different significance, such as

• Different production methods and their special physics

• Different 3D printers and their machine-specific influence on the production process

• Differing metal powder quality

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A very high number of machine input parameters (up to 200) is involved in AM processes, all having an impact on the achieved behavior of the final parts. Prior to producing the parts, you have to answer questions like

• What is the best support structure strategy in terms of location and properties?

• What is the best build-up orientation?

Complex physical interactions cause an inconsistent quality of the produced parts.

Non-optimal part design for manufacturing leads to

• Incorrectly produced or even failed parts (cracks), due to

… Distortion

… Residual stress

How Simufact Additive can help you solve these issues


Simufact Additive is a powerful and scalable software solution for the simulation of metal-based additive manufacturing processes.

Simufact Additive helps you to produce AM parts first-time-right:

• Deformation of the manufactured part and of the base plate

• Minimize residual stress

• Optimize the build-up orientation

• Optimize the support structure

• Condition the part after heat treatment, base plate and support structure removal

In the future also:

• Predict the microstructure

• Indicate criteria-based part failure

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Simufact Additive puts its focus on Powder Bed Fusion processes including Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), LaserCUSING®, Electron Beam Melting (EBM), and more. Deposition processes are currently covered by Simufact. welding.

Using the macroscopic approach, you get simulation results within a few minutes, which predict the tendency of stresses and distortions.

Accurate results can usually be obtained in just a few hours.

Achieve your business goals with Simufact Additive

Replace time-consuming testing with simulation methods!

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Employ Simufact Additive process simulation and save time and money:

• Shorten your learning process dramatically

• Run more variations prior to the production

• Shorten time-to-market

• Increase machine/manpower availability and productivity

• Reduce material and energy consumption costs

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Simufact Additive covers the core manufacturing process chain including

• Additive Manufacturing

• Heat Treatment / stress relief process

• HIP process (mechanical influence)

• Cutting & removal (of the support structures and plate)

 

5 reasons why Simufact Additive

will lead the way

  1. Problem solver

Simufact Additive helps you solve the No. 1 issues with 3D metal printing:

a. Significantly reduce distortion

b. Minimize residual stress to avoid failures

c. Optimize the build-up orientation and the support structures

2. Strong concept

Simufact Additive´s multi-scaling approach combines the best approaches in one unique software solution – from an extremely fast mechanical method to a fully thermo-mechanically coupled transient analysis with highest accuracy in simulation results.

3. Special purpose software

Simufact Additive is a specialized software solution dedicated to AM process simulation.

4. Best-in-class GUI

Simufact Additive comes with an intuitive and user-friendly GUI ensuring an extraordinary user experience. The flexible GUI concept allows machine and application-specific dialogs aligned with the real process work flow.

5. Sophisticated Technology

Simufact Additive is based on MSC´s proven MARC solver technology

• Leading solution for non-linear numerical simulations

• Covering a broad range of physics

• Further dedicated advancement for AM purposes

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Best-In-Class GUI for AM process simulation

Simufact Additive comes with a best in-class GUI ensuring an extraordinary user experience:

• User-friendly, intuitive use

• Fewer icons for a better usability

• Context sensitive, use right mouse click

• Prepared for application- and machine-specific dialogs

• Support of complex models

• GUI is oriented to real AM workflow

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