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Finished product geometry

Mass distribution analysis

Rolled part design

Calibration plan

3D rolled part geometry

3D roller geometry

Roller technical drawings

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VeraCAD Reducer Rolling Design Software

 

VeraCAD is a process and roller design platform developed for reducer rolling applications.

Reducer rolling is a preforming operation in hot forging production lines, where an appropriate preform shape is given to the billet in order to obtain better die filling and reduce the flash size, which leads to a considerable reduction in material costs as well as increase in the product quality.

VeraCAD automatically creates process design based on the limiting reduction ratios of different cross section types, which are empirically determined by the reducer rolling machine builder SMS Eumuco. VeraCAD also allows the designer to review and modify all design parameters, so that designer can combine his or her experience with VeraCAD to obtain an optimum design.

After the completion of the process design, 2D technical drawings and 3D models of the rollers can be created by a single click. Thus, compared to the conventional methods, it is possible to finalize the design process in a much shorter time by utilizing VeraCAD.

All designs made by using VeraCAD can be simulated with Simufact.forming for verification prior to the manufacturing of the rollers. All 3D roller and workpiece geometries with required symmetry conditions and positioning, which are necessary for the simulation, are created automatically by VeraCAD. Thus, all time consuming part modeling work can be eliminated which leads to a very short simulation model creation time.


Reducer Rolling Design in 7 Steps


Step 1 - Importing the finished part geometry: 3D model of the finished part can be imported into VeraCAD in IGS, STL, EDX or VDA formats.

 

Step 2 - Mass distribution analysis: In order to determine the geometry of the rolled part and the initial workpiece dimensions, mass distribution of the finished part is analyzed by taking into account the amount of flash.

 

Step 3 - Design of the rolled part: Designed rolled part, which is based on the mass distribution analysis is revised and necessary modifications are made to the cross sections (oval, square, circle, etc.) or dimensions.

 

Step 4 - Calibration plan: Number of passes can be either calculated by VeraCAD or defined by the designer. Calibration plan is automatically generated by VeraCAD for the selected number of passes. Design proposal of VeraCAD can be optimized by reviewing and modifying the reduction ratios and other design parameters.

 

Step 5 - Creation of 3D part models: 3D part models for all passes can be generated with a single click. These models can be saved in IGS, STL, EDX or VDA formats.

 

Step 6 - Creation of 3D roller models: 3D roller models for all passes can be generated with a single click. These models can be saved in IGS, STL, EDX or VDA formats.

 

Step 7 - Creation of technical drawings: By using the drawing templates in VeraCAD, 2D technical drawings for all rollers can be created with a single click. These drawings can be saved in IGS format for further editing purposes.

 

VeraCAD - Highlights
VeraCAD - Workflow
VeraCAD - Mass Distribution Module
Reducer rolling simulation example (Pass 1)
Reducer rolling simulation example (Pass 2)

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