MSCSuperForge Value Story at Thyssen

1
MSC/SuperForgeValue Story at Thyssen

2
Case Study

• Thyssen Umformtechnik GmbH
• part of German industrial giant Thyssen AG
• turbine blades for power generation turbine
  manufacturers
• No 3-D forging simulation tool so far
• use of CAPS-Finel for many years
• CAPS-Finel is only 2-D
• Strong need for 3-D capability

3
3-D Forging Benchmark

• Participants
• MARC Germany GmbH (MARC/AutoForge)
• Transvalor SA (FORGE3)
• MacNeal-Schwendler (EDC) BV
• (MSC/SuperForge)

4
3-D Forging Benchmark

• Closed-die hot forging of a titanium turbine
  blade (length about 1.2 m)
• Process data supplied by Thyssen
• Geometry of dies and preform delivered in IGES
  format

5
Outcome of Benchmark

• MARC gave up !
• MARC/AutoForge could not even get started
  (convergence problems)
• FORGE3 did not succeed !
• Only the very first beginning could be shown
• Full run would take 20-29 CPU days (estimation of
  Transvalor)
• MSC/SuperForge was successful !
• Good agreement with actual forging process
• Full run took only 18 CPU hours !

6
Why did MSC/SuperForge excel ?

• No remeshing techniques required
• Excessive processing times avoided
• No user intervention required
• No numerical problems in solution
• Robust computational algorithms
• No tricks and tweaks needed enabling lower
  level of simulation experience

7
Why did MSC/SuperForge excel ?

• Thin regions of turbine blade captured accurately

8
Why did MSC/SuperForge excel ?

• Simulation model rapidly generated from IGES
• Tedious clean-up work avoided by fast and
  efficient sewing of non-congruent surfaces

9
Thyssens Decision

• To Purchase MSC/SuperForge !