Altair Case Studies SUNGJIN FO-MA's Use of AFDEX for Improved Quality and Productivity in Automobile Component Precision Forgings

	SUNGJIN FO-MA's Use of AFDEX for Improved Quality and Productivity in Automobile Component Precision Forgings Altair

SUNGJIN FO-MA's Use of AFDEX for Improved Quality and Productivity in Automobile Component Precision Forgings

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation
Applicable Industries	Automotive
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Digital Twin Virtual Reality
Services	Testing & Certification
Challenge	SUNGJIN FO-MA Inc., a global company specializing in cold forging, faced a significant challenge in the prediction of precision forging processes with springback. Precision forging is a process where tight tolerances are a must, and the phenomenon of springback has a significant influence on the final shape of the product. Conventional forging processes are followed by cutting or trimming to achieve the final shape of the desired product. However, in precision forging, the springback phenomenon has to be considered during process design. The company was particularly concerned with the forging process of the intermediate yoke, a critical steering component, where the springback phenomenon is predominant in the region between the two ears. Read More
About Customer	SUNGJIN FO-MA Inc. is a global company that specializes in cold forging. The company, established in 1986, prioritizes customer satisfaction and believes in constant and strategic innovation for sustainable growth. It has received the SQ Mark certificate from Hyundai and Kia Motors – Forging in 2001 and the INNO-BIZ certificate from the Korean government due to its heavy emphasis on innovation and expertise in forging technology. Over the years, SUNGJIN FO-MA has received various technical excellence awards and strongly advocates the use of simulation technology to achieve the best quality at a competitive price. The company attributes its long-term success to its consumers, employees, and technology. Read More
Solution	To tackle this challenge, SUNGJIN FO-MA turned to the elasto-plastic module of AFDEX through the Altair Partner Alliance. The company had realized the importance of FEM simulation of forging processes long back and now wanted to accurately predict the springback phenomenon. The intermediate yoke's forging process was simulated using AFDEX. During the unloading of the punch (5th stage), the two ears came closer towards each other due to springback. This springback amount was predicted and compared with experiments, and it was found that the simulation results matched very well. The use of AFDEX allowed SUNGJIN FO-MA to better design their process, increase productivity, and produce high-quality components. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Applicable Industries

Automotive

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Digital Twin

Virtual Reality

Services

Testing & Certification

Challenge

SUNGJIN FO-MA Inc., a global company specializing in cold forging, faced a significant challenge in the prediction of precision forging processes with springback. Precision forging is a process where tight tolerances are a must, and the phenomenon of springback has a significant influence on the final shape of the product. Conventional forging processes are followed by cutting or trimming to achieve the final shape of the desired product. However, in precision forging, the springback phenomenon has to be considered during process design. The company was particularly concerned with the forging process of the intermediate yoke, a critical steering component, where the springback phenomenon is predominant in the region between the two ears.

About Customer

SUNGJIN FO-MA Inc. is a global company that specializes in cold forging. The company, established in 1986, prioritizes customer satisfaction and believes in constant and strategic innovation for sustainable growth. It has received the SQ Mark certificate from Hyundai and Kia Motors – Forging in 2001 and the INNO-BIZ certificate from the Korean government due to its heavy emphasis on innovation and expertise in forging technology. Over the years, SUNGJIN FO-MA has received various technical excellence awards and strongly advocates the use of simulation technology to achieve the best quality at a competitive price. The company attributes its long-term success to its consumers, employees, and technology.

Solution

To tackle this challenge, SUNGJIN FO-MA turned to the elasto-plastic module of AFDEX through the Altair Partner Alliance. The company had realized the importance of FEM simulation of forging processes long back and now wanted to accurately predict the springback phenomenon. The intermediate yoke's forging process was simulated using AFDEX. During the unloading of the punch (5th stage), the two ears came closer towards each other due to springback. This springback amount was predicted and compared with experiments, and it was found that the simulation results matched very well. The use of AFDEX allowed SUNGJIN FO-MA to better design their process, increase productivity, and produce high-quality components.

Impact #1	The use of the elasto-plastic module of AFDEX allowed SUNGJIN FO-MA to accurately predict the springback phenomenon, leading to a better process design and increased productivity. The simulation results matched very well with the experiments, providing the company with a reliable method to predict and manage the springback phenomenon. This has resulted in high-quality components and increased customer satisfaction. The company's technical team is looking forward to continuously improving their process design and forging processes to remain on top of the business in the coming years and remain a globally competent cold forging company.

Impact #1

The use of the elasto-plastic module of AFDEX allowed SUNGJIN FO-MA to accurately predict the springback phenomenon, leading to a better process design and increased productivity. The simulation results matched very well with the experiments, providing the company with a reliable method to predict and manage the springback phenomenon. This has resulted in high-quality components and increased customer satisfaction. The company's technical team is looking forward to continuously improving their process design and forging processes to remain on top of the business in the coming years and remain a globally competent cold forging company.

Benefit #1	Reduction in product development time
Benefit #2	Highly accurate predictions of deformation
Benefit #3	Increased component quality through optimal process design

Benefit #1

Reduction in product development time

Benefit #2

Highly accurate predictions of deformation

Benefit #3

Increased component quality through optimal process design

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Overview

SUNGJIN FO-MA's Use of AFDEX for Improved Quality and Productivity in Automobile Component Precision Forgings

Operational Impact

Quantitative Benefit