The challenge of Cold Forging design and
how eesy products can support the design engineer.
冷锻设计的挑战和eesy 模拟产品如何支持设计工程师！
State of the art:
Cold forging process design is still highly based on empirical rules and experience.
整体上讲冷锻工艺流程的设计还十分依赖于经验主义的规则。
The challenge for the engineer is to find the right progression – if possible from the start of a project. Normally he will refer to other parts he designed in the past or to available design drawings of similar parts and tries to find a progression that will work.
工程师们所面临的挑战是如何找到最正确的工艺流程-可能的话在设计最开始时。通常工程师们所采用的方法是根据以往设计过的类似的零件的经验来试图找到可行的工艺流程。
Based on this he has to design the tooling. Again he will refer to available drawings of other designs and will try to modify for his purpose. He may ask tool makers as well to consult him.
然后根据这个想法来设计模具。在设计模具时他们会再一次以其它现有的可利用的设计图纸为依据，来做调整以实现他们设计的想法。通常他们也会让模具制造商提供一些建议。
After waiting for the first set of tooling he will go on the machine for first testing. Normally the part will not look as wished by him. In the worst case it will not work out at all.
最后, 在第一组模具做好之后他们开始到机器上试样。遗憾的是通常打造出来的产品并不是他们最想要的。有时甚至和他们的目标相差很远.
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Cracking in the part (screw) Separation of material (cup)
如：裂痕（螺丝） 材料分离（杯部）
Now a phase of testing and adjusting – or even re-designing – is entered. At the end after a long period of testing and changing the part can be produce or the engineer has to give up finally.
如果有以上类似的情况出现，接下来就会需要一系列的测试和调整-甚至重新设计。经过一段长时间的不断测试和改进这个产品可能调整到可生产的状态，或也有可能最终放弃。
Punch failure (nut) Punch failure (retainer)
如：上模失败（螺帽） 上模失败（弹簧座）
Die failure (bolt) Die failure (screw)
如：下模失败（螺栓） 下模失败（螺丝）
Even in case of success he is not sure to have found the best way to make the part. So then during industrial production optimization may take place. But this is difficult because new testing conflicts with production requirements.
另外要提到的是即使设计成功了可工程师们并不确定他们是否在用最佳的方法来生产这个产品。所以在接下来的生产中他们会想办法不断地再优化最初的设计。但实际上这样做是很困难的，因为不断地测试和保证生产的要求总是相矛盾的（测试会占用生产机器和生产时间）。
So at the end the engineer is normally happy if he has supplied a progression and tool design that is just working.
所以如果工程师们所提供的生产流程可以运行、模具可以使用，他们还是可以接受的。
What can eesy software help the engineer?
那现在essy 软件能怎样协助工程师们达到理想状态呢？
First of all eesy software enables the engineer to test his progression idea before having made any detailed drawing even. He will see any underfilling, folding or air enclosure. He can even see whether the part may crack during forming due to stresses.
首先，essy软件能帮助工程师们甚至是在完成图纸的细节设计前来测试他们的工艺流程设计的想法是否可行。工程师们可以通过essy软件观察到他们的设计是否会产生材料的叠痕，材料填充是否不完整，或是否有空气被放入等。他们甚至可以通过essy软件看到是否会由于应力的原因而造成产品在成型过程中的断裂。
Forlding (nut) Underfilling (srew)
如：材料叠痕（螺帽） 材料填充不饱满（螺丝）
He can perform several variations or versions of progressions without making any tooling or interrupting the production for testing.
现在，在不需要生产模具和为了测试样品而停止机器正常生产的前提下，工程师们可以用essy软件来做有关工艺流程设计的各种版本的再设计、再调整和改进。
So after having simulated some variations he can chose the best one for further design.
最后，工程师们在使用essy软件模拟了各种变化和调整后他们能够为进一步的设计选出一个最佳的设计方案。
Finished simulation-optimized design (spark plug)
如：模拟结束-优化了的设计（火花栓）
In this stage he systematically analize loads and stresses to construct the right tooling. The eesy tool design software allows the engineer to calculate the optimized tolling for his progression design and related to the machine to be used.
而工程师们在这个阶段必须要能分析出机器的载重量和应力值等来生产出正确的模具。而essy所提供的模具设计的软件恰恰可以协助工程师们为他们的工艺流程设计计算出最理想的模具结构和最适合的机器设备来进行生产。
Punch analysis (extrusion) Die analysis (extrusion)
如：上冲模的分析（强缩） 下冲模分析（强缩）
Then the engineer will order the tooling. After the manufacturing of the tooling the first trial out on the machine will run – as witnessed by customers repeatedly.
然后工程师们可以开始定制模具。而模具生产好后在机器设备上的第一次尝试可以运行自如－这一点被我们的客户们不断地验证。
Die design calculation Die stress analysis
模具设计计算 模具应力分析
Conculsion：
总结：
All the trial and error process is shortened drastically. Necessary variations are studied during simulation before any tooling is made even. Production will not be interrupted for unnecessary testing and the production process design will be optimized from the beginning. So not only good quality、productivity, but good tool life can be expected a well.
通过正确地使用essy软件，所有有关工艺流程设计的不足和调整过程都被有效地缩短了。一些必要的改进和优化在实际生产模具之前已经通过模拟得到最佳的调整。生产设备不需要因为测试样品而停止正常生产。整个工艺流程在设计最初已接近最理想状态。这样，不仅能够保证产品质量、产品生产率，而且还可以保证模具的使用寿命！
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