Aluminium and copper alloys belong to the same technological class of highly formable non-ferrous alloys. They share a number of important characteristics, including high ductility and many active slip systems, strong sensitivity to temperature and strain rate, and the fact that recrystallization/recovery are central to process optimization. In addition, these materials exhibit strong thermal-mechanical coupling. In general, they are easier to form than Ti and many Ni alloys.

However, despite these similarities, there are also significant differences between them. These include very different density, very different melting point / hot-working temperature, and different forming loads. They also differ in terms of oxide films and tribology, stacking-fault energy and recrystallization behaviour, as well as in the links between forming history and final properties.

WIRE DRAWING

• Sequence optimization for round and profile wires

• Fast simulation of multi-pass drawing

• Prediction of drawing load, stress, and strain

• Optimization of die angle and bearing length

• Reduction of development time and trials

WIRE ROLLING

• Design optimization of each roller profile

• Optimization of wire drawing sequence

• Prediction of load, torque, and contact pressure on each roller

• Analysis of metal flow and profile filling

• Evaluation of roll stresses and distortion

COMPACTION IN DIE AND ROLLS

• Simulation of conductor compaction in stranding machine

• Compaction ratio, reduction, and metal flow analysis

• Prediction of contact pressure between wires as well as of load and stresses

• Analysis of rolling torque and shape evolution

• Optimization of groove geometry and parameters

CONFORM EXTRUSION

• Optimization of die design and extrusion flow

• Control of material and tool temperature

• Profile geometry and structure analysis

• Prediction of pressure and temperature

• Analysis of metal flow and structure

TUBE DRAWING

• Prediction of wall thickness and stresses

• Prevention of damage and defects

• Optimization of tooling design and expansion parameters

• Evaluation of mandrels and die parameter configuration

• Prediction of wrinkling and fracture risk

EXTRUSION

• Metal flow analysis for direct and indirect extrusion

• Prediction of heating/cooling and defects in the profile

• Optimization of die design and tool life

• Equal channel angular extrusion

• Die stresses and extrusion pressure control

BULK AND SHEET METAL FORMING

• Evaluation of bulk and sheet metal forming processes

• Specific bending, punching, and cutting processes

• Prediction of stress, strain, and temperature

• Early detection of defects and high die stresses

• Elimination of practical tests and trials

COLD FORMING

• Dimensional analysis of the formed part to assess forming quality

• Detection of forming defects, including evaluation based on damage criteria

• Prediction of load and verification of cold forming press capacity

• Estimation of tool life

• Identification of critical stress zones in dies and punches

TUBE ROLLING

• Special mesh adaptation in the deformation zone

• Volume constancy throughout the deformation process

• Accurate and fast calculation

• Consideration of movement and support of all tools

• Control of geometry and deformed metal structure