ANALYSIS TYPE / 08
Manufacturing Process Simulation for Better Products
Overview
Manufacturing simulations aim at replicating the process of manufacturing in a simulation environment using FEA-based numerical approaches. These simulations provide critical insights into the product which undergoes manufacturing processes, such as deformations, stresses, and plastic strain. Processes such as sheet metal forming, hemming, stamping, and welding can be performed using Ansys Structural tools. Manufacturing simulation covers stamping, casting, welding, additive manufacturing, and assembly process modelling — predicting springback, residual stresses, distortion, and forming defects to optimise tooling and process parameters before physical trials.
Industries Served
Deliverables
Key Aspects
Simulating deep drawing, stamping, and hydroforming to predict thinning, wrinkling, springback, and fracture — enabling die and blank optimisation before tooling is cut.
Modelling temperature history, residual stress, and distortion during welding and heat treatment — predicting final part shape and informing fixturing and sequence strategies.
Simulating metal flow, solidification, porosity, and shrinkage in sand, die, and investment casting — predicting defect locations and optimising gating and risering design.
Simulating layer-by-layer thermal cycling, residual stress, and distortion in powder bed fusion and directed energy deposition — enabling support structure and scan strategy optimisation.
Connect with our structural simulation team to discuss the right approach for your application.
