Sammy Consulting leverages Simufact software for simulating various mechanical processes including forming, welding, and 3D printing, achieving satisfactory results in automotive and industrial components. The document outlines various applications of Simufact, such as analyzing stress, temperature, and behavior under loads, along with unconventional forming processes and innovative design concepts. Multiple simulation examples are provided, highlighting the software's accuracy in predicting forces and the potential for product optimization.

1. Sammy Consulting
Creative Simulation of products using Simufact
Presenter
Dr Vasant Khisty
Sammyconsulting@gmail.com
+919860500638
Crash test

2. Sammy Consulting
Research oriented consulting

3. • Simufact is a software used for simulating forming, welding mechanical joining and 3D printing process
• Simufact is engineered for process simulation.
• Sammy Consulting has experimented with Product simulation using Simufact.
• Simufact has solvers based on MSC Marc and MSC Dytran
• It’s a software which uses Finite Volume and Finite element solver
• Sammy Consulting has used its imagination to simulate automotive, industrial components
• Results were satisfactory and useful for static loading and analysis of stress and temperatures.
Synopsis of Presentation
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4. Have fun Simulation of moving the moon from earth
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5. Simulation of Hook Failure
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The hook showed the elongation of the eye hole but the hook end gets elongated later
https://www.youtube.com/watch?v=Irtgqbp9dOg

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10. Around 9000 N force required to bend the
Lower arm. Strength increased by
Adding a stiffener in between the legs.
This type of intermittent load can be observed
When the car hits a kerb or the divider.
The lower arm normally yields without breaking.
MSC Apex can be used to change the positions of
Stiffner and see the difference in static and dynamic
Load.
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11. Damaged planet gear
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A one degree misalignment of the sun gear damages the pinion

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It requires and archer around 25 N
To pull back a bow. We used simufac
to check how much force a short bow
Requires to be pulled back by 70 mm
And the force required was 26 N
This is the accuracy of SIMUFACT in
Predicting the forces required.
This is another example of
Using SIMUFACT for non
Forming application
Have funLord Rama
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15. Using Twisting Technology to increase strength
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16. Crank Pin assembly
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17. Breakage of chain links
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18. Bending of a wrench
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19. Hydro locking of connecting rod due to rain water
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When ever the water enters the engine
The engine gets locked as the piston cannot
Compress the water hence the con rod bends
This phenomenon is called Hydro locking

20. Heat generation in lubricated and un lubricated piston rings
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21. Simulation of Damaged ball due to eccentric shaft
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22. 18 Tons force for bending
4 Tons for bending
Twisted 60 RCS Bar
60 Rcs Bar
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This simulation proves that twisted bars require 4 times bending force and twisted forgings can be a answer for light weighting

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24. Railway Axle breakage due to interrupted track
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https://www.youtube.com/watch?v=mBktZj67eYA

25. Twisted chassis frames
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26. Impact on railway tracks
Railway tracks can have severe stresses when some thing like a goods train passes over them

27. Unconventional Forming process Simulations
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28. Hollow double gear forming
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A hollow tube can be forged from
Both ends and a natural piping can be
created at big ends to optimise
Raw material

29. Wrap Forging Technology by Sammy consulting Wrapping another part over a machined part
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A revolutionary concept where a machined component can be wrapped over
By another forging. Two different materials can be forged together to
Form one component.

30. Integrating a bull gear with a shaft for cost reduction
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A bull gear is permanently forged
With another shaft using a
Punch to push the material
Inside the key hole.

31. Progressive extrusion reduces force on the
Press.
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This is a combination of tools
To check the load on progressive extrusion
It requires half the force for forward extrusion
Bu using two tools instead of one
https://www.youtube.com/watch?v=X47p2JL4xys

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A radical concept by forging two components using a split sleeve and making a permanent Bi metal forging

33. Simulation of Broaching process
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Broaching is a cutting process but the purpose was to check stress on component and tool temperature

34. Simulating if twisted plates have more compressive strength
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35. Best quality shear happens when
1/ The diameter of bar is exactly equal to diameter of die
2/ When the bar is tightly clamped to avoid reaction
3/ When cut piece is calmped from bottom to avoid
Bending before shearing
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Simulating variables in Shear
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36. Twisting 4 square bars to make axles
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Four different rods were twisted together to check if Simufact can twist 4 bars together and it did
https://www.youtube.com/watch?v=8IrorrGLvpk
For videos click these links
https://www.youtube.com/watch?v=e700RIFH2AQ
https://www.youtube.com/watch?v=f3XOqSK1WMc
https://www.youtube.com/watch?v=w8eUbZfMwpI

37. Thank You Simufact
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