Predict Die Failure. Optimize Heat Treatment. All in One Tool.
Why Traditional Simulation Tools Don’t Cut It
Most die shops rely on guesswork, expensive software, or outdated spreadsheets. Simulation tools are powerful — but they’re also slow, expensive, and built for engineers in big OEMs.
That’s where our tool changes the game:
- Smart Python backend based on real die shop logic
- Predicts wear, cracks, and thermal fatigue instantly
- Recommends heat treatment settings based on your steel
- Runs right on your website — no installs, no licenses
How We Stack Up
| Feature / Tool | Our Web-Based Tool | Simulation Software | Manual Methods |
|---|---|---|---|
| Platform | ✔ Web | ✖ Desktop Only | ⚠ Paper / Excel |
| Die Life Prediction | ✔ Real-Time | ✔ Slow | ✖ Guesswork |
| Thermal Analysis | ✔ Lightweight Sim | ✔ Full Sim (Slow) | ✖ Not Available |
| Heat Treatment Advice | ✔ Built-In | ⚠ Limited | ✖ Manual Lookup |
| Learning / AI | ✔ Adaptive | ✖ Static | ✖ None |
| Cost | ✓ Affordable | 💰 Expensive | ✓ Cheap (but risky) |
| Setup Time | ⏱ Minutes | 🕒 Weeks | 📄 Varies |
Designed for Real Die Shops
This isn’t simulation software. It’s smarter, faster, and made for:
- Tool & die makers
- Forging shops
- Maintenance engineers
No training. No complex menus. Just answers — instantly.
💻 Python Code Examples
These Python snippets analyze Fluent simulation data and help detect failure risks, thermal stress, and hardness loss — in real-world forging workflows.
📊 Fluent Physics Analysis
Loads max temp/stress from Fluent, calculates zone averages, and flags high-risk zones based on thresholds.
- ✅ Inputs: Zone-wise temperature & stress values
- ⚠️ Flags: High average temp or stress (> 800°C or > 600 MPa)
- 📌 Output: Suggests adjusting forging or cooling if risk is high
⚙️ Fatigue Risk Based on Cycle Count
Tracks plastic strain over cycles and calculates fatigue damage ratios to predict cracking likelihood.
- 🔁 Inputs: Number of cycles, plastic strain per zone
- 📉 Tracks: Fatigue growth with material models
- 🚨 Output: Warns if zones exceed safe fatigue limits
🧪 Hardness Drop Risk Detection
Checks hardness maps for any zone falling below 450 HV, often indicating softening or tempering defects.
- 🧾 Input: Zone hardness values from Fluent export
- ❗ Flag: If hardness < 450 HV
- ✅ Output: Highlights inspection zones
Start Now: Customize Your Die Failure Prediction
Select your material, heat treatment, and other options below. We'll follow up with a tailored solution within two business weeks.
📅 Book a Demo
Ready to see ForgeSense AI in action? Fill out this form and we’ll schedule a short call to walk you through it.