Simtec offers advanced digital twin simulation framework for HIP process optimisation

Simtec Soft Sweden AB, based in Lund, Sweden, has introduced a simulation framework for Hot Isostatic Pressing (HIP) processes that uses a digital twin to provide insights into the complex thermal, gas flow, and material behaviours during HIP operations. Simtec’s holistic methodology integrates advanced computational tools as well as robust mathematical and physical models.

Industries such as aerospace, automotive, energy and Additive Manufacturing demand precise material properties and defect-free components, explains Simtec. Traditional trial-and-error methods for HIP processes are costly, time-intensive, and inefficient.

Simtec’s digital twin simulation framework optimises thermal management, reducing operational costs, and enhancing product quality. By incorporating Computational Fluid Dynamics (CFD), advanced algorithms, and fully coupled physical models, Simtec delivers accurate predictions of temperature gradients, gas flow, and material responses, enabling consistent, high-performance results.

In addition to thermal field simulation modules, Simtec has developed a Solid Mechanics Module that offers fully coupled stress, strain, and deformation calculations based on 3D thermal history simulations.

Simtec’s simulation software models the entire HIP process using CFD methods, advanced algorithms and robust physical models to numerically solve the complete governing equations for heat transfer, gas flow, and material behaviour. Unlike simplified empirical formulas, Simtec’s models capture the intricate interactions of radiation, convection, and conduction within the HIP furnace and the material itself, providing detailed insights into thermal dynamics and temperature gradients throughout the machine.

Key equations solved by Simtec:

Simtec’s models enable:

• Thermal profile analysis: Simulates heat distribution throughout the furnace.
• Gas flow dynamics: Captures interactions between gas flow and the sample.
• Thermal-mechanical behaviour: Predicts material responses during heating, holding, and cooling.

The mathematical framework looks to ensure precise predictions of thermal gradients, pressure distributions, and material behaviours at every stage of the HIP process.

Simtec software also offers:

1. Multi-physics integration: Fully coupled simulations of flow, heat transfer, mass transfer, pressure, and chemical kinetics. It offers comprehensive modelling of specialised thermal processes, seamlessly integrating thermodynamics, fluid dynamics, and kinetics.
2. High-Performance Computing (HPC) optimisation: Supports parallel computing and GPU acceleration using Nvidia GPUs. As well as high-performance algorithms to ensure rapid and reliable completion of complex simulations, overcoming convergence challenges often encountered with other mainstream software.
3. Efficient radiation modelling: Critical for high-temperature and high-pressure furnace processes and combustion. Simtec’s proprietary EERSM (Efficient and Enhanced Radiation Simulation Method) delivers efficient, accurate, and validated radiation results across various applications, including turbulent combustion and high-pressure processes.
4. Ultra Rapid Convergence (URC) method: Speeds up computations by over 30 times without compromising accuracy. Tasks that previously required a full day are now completed in just over half an hour, ensuring rapid turnaround times for demanding projects.
5. Reliability in complex scenarios: Simtec’s advanced algorithms and HPC capabilities make it ideal for intricate simulations, including high-pressure, high-temperature, and chemically reactive environments. It avoids the convergence issues commonly seen in many mainstream commercial simulation tools, ensuring reliable results for challenging applications.

Key features of Simtec’s digital twin

1. Thermal profile optimisation: Ensures uniform heat distribution across components to minimise thermal stresses and defects.
2. Energy efficiency: Optimises heating schedules, reducing energy consumption while maintaining material integrity.
3. Predictive analytics: Identifies risks like overheating or uneven cooling before they impact results.
4. Design validation: Virtually tests and refines new part designs under specific thermal conditions.

Benefits for the HIP industry

With robust models and predictive capabilities, Simtec ensures HIP processes are efficient, scalable, and sustainable.

Simtec’s simulations help manufacturers optimise furnace performance, reducing cycle times and energy use. As well as minimising costs through waste reduction, it can enhance product quality with uniform material properties and minimal defects. By tailoring simulations to specific materials and processes, Simtec can meet client’s unique needs and deliver a transformative approach to HIP operations.

Simtec’s digital twin simulations extend beyond HIP processes to address Additive Manufacturing post-processes such as debinding and sintering, as well as other thermal operations requiring precise control.

www.simtecsoft.com

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