Recently  Brawo  has  acquired   powerful software tools, which are used to simulate the  manufacturing processes, such as forging,   mechanical machining  and dimensional inspection.  Therefore our engineers are in a position to modify and correct errors during the simulation, by analyzing the effects of the planned processes and adjusting any causes of malfunctioning of the processes before production starts.  All this sensibly reduces the manufacturing lead times of new items and allows our engineers to identify defects, especially for what concerns the forging stage, otherwise hardly noticeable on the physical pieces, but potentially dangerous in their final application.  In particular,  having to cope with increasing  requests from our customers  to manufacture  forged pieces with complex  shape and completely free of defects, the preliminary simulation has become an integrated part of our design process as far as forging dies are concerned.  Once that the mathematic model  of the forging tool has been produced and strictly before  proceeding to its manufacturing,  all the significant features which could influence the positive outcome of the forging operation are carefully analysed  through the simulation.  Features such as flow, speed and temperature of the material are measured at any stage of the deformation  process. If necessary, issues can be addressed through modifications of the tools and of the scheduled parameters of the process.  This gives us the advantage to be in a position, before tools have been already manufactured, to intervene on every feature without interferences or limitations.   This,  generally, enables   Brawo  to  achieve  an  optimal result with costs and timing  compatible with our customers’ expectations.   As far as the mechanical  machining are concerned, the simulation enables us, as in the  case  of the forging stage, to verify  the consistency of every detail  of this process and of the  tools  designed for this purpose.

By exactly following every aspect of the real process,  such activity reveals beforehand and in practice any  errors, particularly geometrical issues, that if not removed,  might be the cause -  in the production stage -  of the impossibility to proceed  (due to tools incompatibility)  or worse,  of dangerous collisions with the movable parts  of the machines used for the production of the parts.   

Furthermore, by comparing the virtual products of the simulation (item completely machined)  with the mathematical model  of reference,  any inconsistency is  immediately  revealed and can then be corrected in that stage,  so that  all tools might reach the production departments, at the beginning of the sampling  or  production stage, within the lead times due and with the expected quality.