This warm formed gear carrier was the subject of a German simulation benchmark. DEFORM-3D results matched the production process with excellent accuracy. Large deformation processes such as this require a very robust analysis, contact and mesh generation capability. In addition to accuracy and robustness, simulation times were very fast. Today, this simulation runs in a few hours on a very inexpensive desktop or laptop computer with no human intervention.
During the development of new forging designs, DEFORM can be used to study die fill, load, energy, strain, adiabatic heating and tool stress analysis. Small defects can be observed prior to committing to production tooling. Multiple sequential trials can be run in days rather than weeks – at a much lower cost.