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FMK(Forge Master Korea) training program

Curriculum

Transvalor FORGE software (Metal forming simulation tool)
Transvalor THERCAST software (Casting simulation tool)
UBECO PROFIL software (Roll forming design & simulation)

Time

AM 09:30 ~ PM 5:30 (8 hours)

Teacher

Teacher
Caurse	Name	Position	Tel.	E-Mail
FORGE and THERCAST Workbench, Opt. FORGE die stress, PROFIL Heat Treatment, User Routine	Hyung-Cheol Lim Se-Hwan Chun Changhyok Choi	Manager Team Manager Director / R&D Center	+82-55-713-9100	support@forgemaster.co.kr

Course F1: Manufacturing processes Analysis Using FORGE NxT Workbench

Training schedule
Day1 : Overview finite element analysis of plastic deformation and practice of the FORGE workbench	FORGE basic theory
	Understanding FE analysis of plastic deformation
	Understanding 2D / 3D analysis
	Practice of 2D hot forging of Crown
	Practice of 3D hot forging of Spindle
Day2 : Practice with pre-processing, solving, and post-processing methods using FORGE workbench	Understanding Hot / Cold forming analysis
	Practice of 2D cold forging of Valve housing
	Practice of coupling analysis from 2D to 3D in cold forging process of Screw
	Practice of die steady state temperature and die stress analysis of Crown
Day3 : Practice of various manufacturing processes using FORGE workbench	Practice of various manufacturing process analysis provided by FORGE
	Induction heating, Austenization, Bar shearing, Die stress analysis of Bushing, Carburizing, Cogging, Deep drawing, Hammer forging, Hot rolling steady state, Orbital forming, Piercing, Quenching, Reducer rolling, Ring rolling, Self Piercing Riveting, Rivet crimping, Tool stack, Washer forming etc
	Practice processes are selected based on trainees feedback
Day4 : Practice of user required manufacturing processes by trainees	Answer questions in this course and accept user requirements
	Practice of user required processes by trainees
	Becking, Long product rolling, Flow forming, Break down mill, etc

Course T1: Casting process analysis using THERCAST workbench

Training schedule
Day1 : Introduction to THERCAST Software and practice of the THERCAST workbench I	Overall understanding of THERCAST software
	Introduction to online help and reference guide
	Introduction to the workbench's pre-processing interface and basic operations
	Practice of the Foundry casting process
Day2 : Practice of the THERCAST workbench II	Introduction to the workbench's post-processing interface and various post-processing options
	Practice of the Ingot casting process
	Understanding thermics, hydraulicis and machanics calculations
	Understanding how to create material files
Day3 : Practice of the THERCAST workbench III	Practice of the continuous casting process
	Understanding how to create a casting machine using continuous casting machine tool
	Understand how to set settings such as performance pass, roll and spray position and number, heat transfer coefficient and spray conditions

Course F2: Optimization using FORGE NxT

Training schedule
Day1 : Introduction to Optimization of FORGE Software and practice of shape optimization analysis	FORGE Optimization Theory -Understanding optimization concepts and algorithms
	Understanding Shape Optimization
	Practice of the shape optimization in 2D hot forging process of Crown -Understanding of optimization method through scale adjustment of initial material, shape coordinate change and shape change using FreeCAD
	Practice of the shape optimization 3D Hot Forging Process of Spindle -Understanding of optimization method through scale adjustment of initial material and shape change using FreeCAD
	Practice of the geometry optimization 3D hot forging process of Camshaft -Understanding how to optimize billets with shape rolled billets
Day2 : Practice of a reverse analysis using FORGE optimization	Understanding Reverse Analysis
	Practice to optimize hot properties of materials through 2D high temperature compression test analysis
	Optimization of nonlinear convective HTC between object and atmosphere through 2D heating analysis
	Optimization of nonlinear convective HTC between object and atmosphere through 3D quenching analysis
	Optimization of shear friction coefficient between material and dies through 2D ring compression test analysis

Course F3: Heat treatment using FORGE NxT

Training schedule
Day1 : Introduction basic concept of heat treatment analysis and practice of a heat treatment process of hot forging	Understand the theory of heat treatment, phase transformation, grain size, chemical element diffusion, etc.
	Practice of the heat treatment analysis of hot forging, heating, forging, cooling, reheating, carburizing, quenching, and tempering process of crown
	Understanding predicted TTT curve and heat treatment material using chemical element and initial grain size
Day2 : Practice of a heat treatment process of cold forging and spray cooling analysis	Practice of the heat treatment analysis of cold forging, heating, quenching and tempering process of Screw
	Understanding prediction model of the hardness of forgings
	Practice of the spray quenching process
	Understanding the settings for the vertical spray

Course F4: User subroutine using FORGE NxT

Training schedule
Day1 : Introduction basic concepts of user routines and practice of writing user subroutines to output modified result values	Understand basic concepts of user subroutines
	Understanding how to set up your environment to use user subroutines for FORGE
	Practice of writing user subroutines to output of the modified result of analysis
Day2 : Practice of writing user subroutines on physical properties, friction and thermal boundary conditions, damage, etc.	Practice of writing user subroutines on modified material properties
	Practice of writing user subroutines on modified friction condition
	Practice of writing user subroutines on modified heat transfer conditions
	Practice of writing user subroutines on modified damage