DEFORM™ is a finite element based process modeling system that is widely used in the design and development of forging, heat treatment and machining processes.  DEFORM™ is widely used in various industries during the development cycle to reduce design iterations, troubleshoot problems and optimize processes.

Process modeling is used in the forging industry to predict metal flow in the die cavity, flow defects and underfill conditions.  Modeling plays an integral role in the optimal design of forging process including preform and die tooling design, analyzing die stresses and extending die life.  Metal forming processes such as extrusion, rolling, drawing and cogging can also be modeled.

Modeling heat treatment process helps to predict residual stresses and resulting heat-treat distortion and microstructural evolution.  The diffusion mechanisms and phase transformations can be modeled.  Inverse heat transfer optimization method has been successfully implemented to characterize the heat transfer boundary conditions accurately.  A variety of heat treatment processes such as austenizing, carburizing, quenching, tempering and stress relieving can be modeled.

Machining simulation can be used to predict the influence of cutting parameters such as cutting speed, feed and depth of cut on chip morphology, temperature, tool wear, and cutting force.  The effect of redistribution of residual stresses during machining on part distortion can be analyzed.  A variety of turning, milling and drilling operations can be modeled.

The wide-ranging use of process modeling in industry is instrumental in the improvement of cost, quality and delivery for nearly two decades.  Examples of DEFORM™ capabilities will be presented, along with the case studies that highlight applications covering forging, heat treatment and machining process design and analysis.