It was due to the efforts of the international consortium that the QFORM3D software was brought out. From the Russian side the development was carried out since 2002 by the QuantorForm company, which is now distributing the software on the territory of the CIS. The software combines 2D and 3D simulation. It maintained the easy interface of the previous software. For 3D simulation it is only required to select solid body models for the dies and the workpiece as the initial geometry data. QFORM3D is used for the simulation of hot, warm and cold forming processes. The software predicts material flow defects, identifies the temperature distribution, assesses the load and consumption of energy for the deformation.

QFORM3D combines 2D and 3D simulation in a single software. It gives the user an enormous advantage. The software maintained completely its broadest functionality and the easy and habitual interface of its 2D predecessor. The only thing required in order to convert to 3D simulation is to select solid body models for the dies and the workpiece, rather than 2D cross-sectional contours as the initial geometry data. All other data are specified in the same fashion as for the 2D computation, using a convenient and vivid Data Preparation Wizard to minimize the probability of casual errors.

The integration of 2D and 3D simulation in the same software package provides a unique opportunity to simulate efficiently the process chains comprising several forging impressions, the first of which have axial symmetry and can be solved fast in a 2D setting (e. g. upsetting and preliminary impressions and the subsequent ones require full-scale 3D simulation. The object-oriented software structure creates a very comfortable and fully integrated user environment. The data preparation goes hand in hand with their display for visual monitoring and the computation is accompanied by the simultaneous graphic display of the results. Thus the software is an efficient tool for the computer assessment of the process, which is much more economical and faster than the debugging of the technology by hit and miss.

The software supports the import of IGES and STEP files to avoid a loss of accuracy in comparison with the case, when data are used in the STL format. In addition, it features a direct interface to SolidWorks (SolidWorks Corp.), speeding up the operation considerably. Surface models of the dies created by PowerShape (Delcam Plc) also can be effectively imported to QForm by means of specially developed facilities.

Using the full and accurate die and workpiece geometry as the initial data and also having the expertise of non-linear approximation for the solution of 2D problems, QFORM3D was the first commercial software to use quadratic finite element approximation in order to solve 3D problems. This allowed a considerable increase in the solution accuracy, a reduction in the loss of volume and a high solution reliability and certainty in the forging flaws prediction. The description of surfaces by the non-linear finite element model allows remeshing as often as needed, without ‘shouldering’ the surface at tight curves, which is characteristic of linear elements.

The software generates a finite element mesh on the die and workpiece surface and inside automatically, restructuring it in the solution process, as required. Since non-linear approximation is the basis, the most intricate and sophisticated fully automatic adaptive mesh generation algorithms can be used. The mesh is made denser at the locations with the highest surface curvature and high solution gradients and is maximally rarefied at the locations, where there is no extensive material flow, to allow for the saving of computation resources. Eventually, an automatically generated mesh guarantees a high solution quality and its accuracy regardless of the user qualification level.

• The software provides the computation of both the 3D forming, when workpieces of an arbitrary shape are forged, and the pre-stressed state of the dies. The forging is calculated with two tools. The tools move rigorously along the Z-axis;
• The initial geometry is imported to QFORM from CAD systems;
• The workpiece and tool material as well as lubricant and equipment are borrowed from the database, which is set up for every user on a case-by-case basis;
• The process parameters (time, final distance between the dies, etc.) are specified using an easy and clear Initial Data Preparation Editor;
• The workpiece deformation is considered with regard for thermal processes. The dies are designed without regard for the thermal field. The heat transfer between the workpiece and the tools is considered by the heat transfer factor;
• When calculating the form change, the software can consider the symmetry axes preliminarily marked in the QDraft graphic module;
• The simulated process steps include the cooling of the workpiece on the air and in the die, forming of arbitrarily shaped workpieces in dies of an arbitrary configuration;
• The workpiece forming steps are calculated for the crank press, hammer, hydraulic and screw presses;
• The process flow is considered as a process chain. Computation of all steps within a process chain, which can include up to 99 steps, is performed automatically;
• Simulation of a single process chain comprising both 2D deformation, e. g. the upsetting of a cylinder-shaped ingot, and 3D deformation has been implemented;
• Automatic simulation of repeated strokes for the hammer and screw press has been implemented;
• The option of removing parts of the workpiece according to a preset contour between the steps, which corresponds to the punching of holes and trimming of flash, has been added;
• The option of cutting off along a preset contour the ‘excess’ material, which goes beyond the focal point of deformation directly in the computation progress, has been added to cut the dimensions of the model and save the time;
• The option of manual positioning of the workpiece before the commencement of a step, including the workpiece displacement, rotation and mirror imaging of the workpiece relative to any axis or plane, has been added;
• The workpiece is simulated as a solid body moving by gravity, friction and inertia, when it is placed on the lower die, to identify its natural stable position before the commencement of forming simulation;
• The pre-stressed state of the dies is simulated under the impact of the contact stresses arising, when the workpiece is formed;
• Besides the automatic mode, the final distance between the dies can be also specified in any point determined by the X and Y coordinates.

To this end, you have to save the solid model in the IGES or STEP format and open it in the graphic editor QDraft. QDraft has also a direct interface to SolidWorks (SolidWorks Corp.), speeding up the operation considerably. Surface models of the dies created by PowerShape (Delcam Plc) also can be effectively imported to QForm by means of specially developed facilities.

The initial data setting is different from QFORM2D – specifying the workpiece shape, you have to specify an arbitrary shape (3D simulation), instead of a round shape (axial-symmetric deformation) or a flat cross-section (flat deformation). All other parameters are set identically with the 2D material flow simulation.

The simulation process advances automatically and does not require any user intervention. The smart system mesh generator provides an optimal finite element mesh in any simulation stage.

A convenient postprocessor ensures the viewing of the simulation results – the deformation, stress, temperature and contact strain distribution in the workpiece, deformation force, work and energy varying, as the ram moves, and finally the stresses, deformations and surface deflection in the tool.