NagForge
Overview
Nagforge is a knowledge based software program
for automatic and manual design of forging sequence for hot and warm
forged parts. It allows the User to capture manufacturing knowledge
and use it to design progressions for similar parts.
NagForge utilizes a combination
of design logic, knowledge-based rules and simple analyses to determine
a forging progression automatically in minutes.The sequence designs
created in NagForge can be tested effortlessly in NAGSIM_Gen.2D FEA
simulation software.
In addition to sequence design,
NagForge has a 'Smart' database and analysis module to store 'Knowledge'
and use it to improve the design and manufacturing processes.
Uses:
- Search its 'Smart' database to find similar
parts and the knowledge available including sequence designs,
lessons learnt, tool life etc. Prevent reinventing sequence design
or spending hours to design a wrong forging sequence.
- Create hot forging part profile from machined
part profile.
- Obtain alternative sequence designs for
forging a part in a few minutes.
- Calculate flash dimensions for closed
die forgings.
- Calculate die angle for Chevron free extrusion.
- Create reusable sequence-design templates
of your own designs or designs from NagForge. Use these templates
to 'Zip through' progression design for similar 'Family of Parts'.
- Automate and standardize sequence design
of similar parts.
- Create DXF output of sequence designs
in a few minutes
- Select optimal blank diameter
- Reduce number of forming operations
- Obtain estimated loads, pressures and
deformation
- Estimate load distribution on a multi-station
machine
- Prevent designs that overload the tooling
or overstrain the part
- Teach forming design to new personnel
Limitations:
- NagForge is not a FEA simulation program.
It can not predict metal-flow defects and stress distribution
in tools.
- Nagforge can be used only for parts with
some symmetry such as parts made on upsetters, closed die forgings
with and without flash, ring rolling and open die forging of symmetrical
and long parts. Parts can have features such as polygons, flats
and splines.
Alternative Forming Progressions
in Minutes
In general, there is more than one forming sequence by which a part
can be formed. The number of designs depends upon the constraints
such as part geometry, material being forged, allowed number of operations,
wire / rod size etc. NagForge has its own design logic to determine
various possible ways a part can be formed. Because the program looks
for all possible designs and applies its logic without fail, NagForge
can come up with design concepts that even experienced designers may
overlook.
Design by Command
'Design by Command' feature allows the user to create his/her own
design interactively in a few minutes. The interactive session, consisting
of questions by the program to determine design intent and the responses
of the user, is saved in a session file. This session file can be
used as a template to create progression design for similar 'Family
of Parts' in minutes.
Objectives of NagForge
'Smart' Database and Analysis Module
- Create and maintain a historic database
of parts designed, quoted and manufactured.
- Capture and retain the knowledge gained
from experience.
- Improve sequence design, quoting and manufacturing
processes.
- Eliminate duplication of effort.
- Reduce print-to-part time.
Search and Analysis Capabilities
- 'Smart' Database Module
- Part: Search for similar parts, parts
with certain features such as hex, lobe etc, parts within specified
length, diameter and volume.
- Design : Existing Auto or Manual designs
for current or similar parts.
- Material - usage.
- Wire /Rod size - usage.
- Forming Machine - usage
- Tool Life - for similar parts
- Cost - quoted and manufacturing.
- Lessons learnt on similar parts.
Template' Designs for
'Similar Parts' or 'Family of Parts'
For any part that is similar to a template in the database, NagForge
can follow the template design / session file to create forming progression
in minutes.
Manual Design
In addition to automatic design, NagForge has a separate module for
creating a forming progression manually. Using computer aided techniques,
the user can quickly construct a forming sequence according to his/her
own concept. The designer can also start from a computer-generated
design and modify it.
DXF Input and Output
In NagForge, a part is constructed using simple shapes called primitives.
The geometry of parts can also be imported from CAD systems such as
AutoCad, SolidEdge etc. The NagForge output including sequence designs
can be saved in DXF format for input to other CAD systems.
Forging Profile from Machined
Part Drawing
Nagforge has a separate module for creating Forging Profile from machined
part drawing. User can specify machining allowance on outside profile
as well as bore. Fillet and corner radii as well as forging draft
angles can be specified.
Automatic Creation of
Analysis File for NAGSIM.2D
For some of the sequence designs, NagForge can create the analysis
file for simulation of the sequence designs in NAGSIM.2D. For new
parts, for which tooling designs are not available, this saves considerable
effort required to create process drawings for FEA simulation.
