VeraCAD is a process and roller design platform developed for reducer rolling applications. Reducer rolling is a preforming operation in hot forging production lines, where an appropriate preform shape is given to the billet in order to obtain better die filling and reduce the flash size, which leads to a considerable reduction in material costs as well as increase in the product quality.

VeraCAD is used to create process design based on the limiting reduction ratios of different cross section types.

After the completion of the process design, 2D technical drawings and 3D CAD models of the rollers can be created by a single click within a few seconds. Thus, compared to the conventional methods, it is possible to finalize the design process in a couple of hours rather than days.

All designs made by using VeraCAD can be simulated by using Simufact Forming for verification prior to the manufacturing of the rollers.

Reducer Rolling Design in 7 Steps
Step 1 - Importing the finished part geometry: 3D model of the finished part is imported into VeraCAD.

Step 2 - Mass distribution analysis: In order to determine the geometry of the rolled part and the initial workpiece dimensions, mass distribution of the finished part is analyzed by taking into account the amount of flash.

Step 3 - Design of the rolled part: Designed rolled part, which is based on the mass distribution analysis is revised and necessary modifications are made to the cross sections (oval, square, circle, etc.) or dimensions.

Step 4 - Calibration plan: Number of passes can be either calculated by VeraCAD or defined by the designer. Calibration plan is automatically generated by VeraCAD for the selected number of passes. Design proposal of VeraCAD can be optimized by reviewing and modifying the reduction ratios and other design parameters.

Step 5 - Creation of 3D part models: 3D part models for all passes can be generated with a single click after creating calibration plan.

Step 6 - Creation of 3D roller models: 3D roller models for all passes can be generated with a single click after creating calibration plan.

Step 7 - Creation of technical drawings: By using the drawing templates in VeraCAD, 2D technical drawings for all rollers can be created with a single click.