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18.01.2023

Simulation as the key to success

For new developments, Hatebur makes the most of the latest simulation methods to validate the feasibility of innovative technological concepts and to achieve the highest level of output and maximum reliability for your forming machines under a wide range of working conditions.

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Such simulations make it possible to check various solution approaches even before sourcing and comparing the first components. In doing so, Hatebur ensures that the expectations for efficient, material‑saving processes can be fulfilled, as well as long, reliable operation.

System simulation of physical-technical systems and installations

Hatebur uses the system simulation not only for the final design validation and adjustment of parameters, but also for a deeper understanding of all physical interactions in the complex high‑performance systems. In order to be truly innovative and a leader in the sector, engineers must understand all influences and dependencies in the functional system to find robust solutions for the challenges. It is therefore essential to model all relevant physical phenomena accurately. If the machine does not behave as expected, a system simulation model offers a unique insight into the physics of all functional subsystems and components, which helps considerably to facilitate troubleshooting and overcome these challenges.

Investment in a system model for functional validation and optimization is worth the effort, not only through a reduced number of prototypes, but also through accelerated machine commissioning. The machine’s behavior is reliably predicable, regardless of its production or assembly status. This is true for purely mechanical, electrical and hydraulic control systems, as well as electrohydraulic and electromechanical control systems and regulation.

“Servohydraulic bar stop” case study

Hatebur puts into practice the physicalforming technology approach that “compressive stress increases deformability” for hot shearing using the servohydraulic bar stop. This minimizes or even eliminates shear fractures. This was reported in detail in NetShape edition 2/2018. The precise power interaction during the shearing process occurs at an interval that is up to five times shorter than that of the blink of an eye. Therefore, particular attention has been paid to the design of 
the process unit (cylinder, servo valve, stroke measuring system, pressure sensors and control unit). The modeling of the drive was performed using SimulationX.

Simulation using the finite element method

Thanks to more in‑depth calculation for individual components or whole functional assemblies, reliable statements regarding load or deformation behavior of a system under operating conditions can be made using the FE method. At Hatebur, we rely on the extremely efficient Ansys software. The starting position for the use of an FEM calculation can differ greatly: Proof of fatigue strength for new or existing systems, weight optimization for a yet more efficient design for kinematic systems, verification of solutions, long before the components are used in practice.

“Production of new forging geometries” case study

For efficient production of new forging geometries, innovative solutions are required when designing the sequence of operation. These new forming sequences have a direct influence on the load of the whole forming machine. In an iterative interaction between the method development and product development, the new requirements from the processes are harmonized with the options of existing and future forming machines. Various load patterns are analyzed in depth using  focused FEM calculations. The focus is on the components, which are directly under load due to the flux of the forming process. Using a comprehensive simulation model, the complete system is displayed with all relevant components.

The requirements from the various forming sequences are systematically calculated using this model. The results, such as voltages, elongations or contact behavior, are then analyzed by the expert team, which discusses optimization possibilities. The approaches disclosed are integrated into the simulation via several iteration steps, which drives the solution finding step by step.

Based on decades of experience of using the finite element method with the Ansys software, geometry optimizations can be designed for key components which facilitate a significant reduction in component loads at particularly sensitive points for new as well as existing load patterns.

Simulation in software development

Work is done with simulations in software development too. New functions are tested after programming in the simulation environment. This reduces the commissioning time and increases the process security. In the event of changes to existing machines, new program parts can be loaded onto the machine control system via remote maintenance after successfully passing tests.

The simulation also comes in handy in the event of difficult conditions in the supply chain. This means that software can be developed and tested for a new machine in the simulation environment, even if the hard‑ware is not yet available.