Simufact Forming 2025.4 Features and Capabilities
Simufact Forming 2025.4 (released late 2025 as a service pack/update in the Simufact Forming 2025 series) is the latest version of the powerful process simulation software from Hexagon (MSC Software) for metal forming, forging, sheet metal forming, rolling, ring rolling, and additive manufacturing processes. This comprehensive tool enables engineers to virtually design, optimize, and validate forming operations, predict defects (cracks, folds, underfill, die wear), analyze material flow, temperature distribution, forming forces, die stresses, and microstructure evolution—reducing physical trials, shortening development time, and improving part quality/yield in industries like automotive, aerospace, heavy machinery, and fasteners.
Version 2025.4 focuses on stability improvements, enhanced solver performance for large/complex models, better integration with Hexagon ecosystem tools, and refinements in usability, post-processing, and specific forming processes (especially hot/cold forging, sheet metal, and ring rolling).
Key Features of Simufact Forming 2025.4
- Advanced Forming Process Simulation:
- Full support for hot/cold forging, closed-die/open-die forging, sheet metal forming (deep drawing, stamping, bending), rolling (profile, ring, thread), extrusion, upsetting, and powder compaction.
- Accurate prediction of material flow, die filling, flash formation, laps/folds, cracks, and surface defects.
- Microstructure prediction (grain size, recrystallization, phase transformation) with integrated material models.
- Solver & Performance Enhancements:
- Optimized implicit/explicit solver for faster convergence on large meshes (multi-million element models).
- Improved parallel computing and GPU acceleration support (where applicable) for reduced simulation times.
- Better handling of very large assemblies and complex die geometries.
- Material & Friction Modeling:
- Extensive material database with temperature-, strain-, and strain-rate-dependent flow curves.
- Advanced friction models (Coulomb, shear, velocity-dependent) and lubrication effects.
- Support for user-defined material subroutines (UMAT/VUMAT) for custom alloys.
- Die Stress & Wear Analysis:
- Coupled die stress calculation (elastic/plastic die behavior).
- Die fatigue and wear prediction (Archard model) for tool life estimation.
- Sheet Metal & Multi-Stage Forming:
- Improved springback compensation and multi-stage simulation chaining.
- Enhanced blankholder force control, draw bead modeling, and wrinkling/flange analysis.
- Ring Rolling & Rotary Processes:
- Dedicated ring rolling module with axial/radial feed control, mandrel/work roll kinematics, and ovality prediction.
- Post-Processing & Visualization:
- Upgraded result viewer with interactive 3D contour plots, section views, vector fields (velocity, stress), and animation export.
- New result templates and automatic report generation (PDF/Word) with customizable content.
- Enhanced damage/failure criteria visualization (Cockcroft-Latham, normalized energy, etc.).
- Usability & Workflow Improvements:
- Streamlined project setup with better template management.
- Improved meshing tools (automatic hexa/tetra, adaptive remeshing).
- Better integration with Hexagon Digimat (composite forming), MSC Apex, and third-party CAD (SolidWorks, NX, CATIA import).
- 2025.4 Specific Refinements:
- Cumulative bug fixes and stability patches for solver convergence, large model handling, and result accuracy.
- Minor UI tweaks and performance optimizations reported in service pack notes.
