Virfac®, a product of GeonX S.A.

GeonX is a high-tech start-up company specializing invirtual manufacturing. Created in 2012 from the enthusiasm of its two founders,and an investment by a group of private investors, GeonX develops and marketsits VIRTUAL FACTORY, Virfac®. This product is based on the finite elementsolver Morfeo, which has been actively developed since 2003, with the aim ofcarrying out massively parallel simulations of various manufacturing processes.

GeonX develops and distributes its integrated softwaresolution Virfac® for simulations of welding (fusion and friction), additivemanufacturing, machining, heat treatment, surface treatment, and damageresistance (crack propagation based on the XFEM). GeonX has clients in Europe,Japan, North America, in the aeronautics, automobile, naval, and nuclearsectors. GeonX’s leading aerospace client is the SAFRAN Group (France).

 Advanced (fusion and friction) weldingsimulation:

Virfac® Welding proposes a transient numerical modelfor a variety of welding processes. The modeling of the thermomechanicalproblem allows the user to accurately predict the level of residual stressesand distortions at the end of the process. The use of Virfac® enables theoptimization of the welding process by modifying the clamping system and/or thewelding sequence in order to improve the design without having to performexpensive experimental works. Accurate results within a feasible time-frame canbe obtained due to Virfac’s massively parallel solver capabilities. Weldingtrajectories can be defined directly from CAD geometry allowing easy definitionof complex and multiple welding paths. These welding features are effortlesslydefined using Virfac®.

 Advanced machining simulation:

An original algorithmic strategy makes Virfac® Machiningefficient for the simulation of multi-pass machining simulations. Relaxation ofstresses generated during upstream processes is often the most critical sourceof distortion during the machining process. In order to predict themaccurately, it is crucial to take the whole sequence of passes into account.Therefore, the level-set (signed distance) is used to represent each path sothat the workpiece can be meshed separately to of the different cutting surfaces.This offers a strong advantage over the classical Finite Element approach whichwould require heavy remeshing operations after each machining step. This methodguarantees that cutting paths are defined in an initial undeformedconfiguration while a deformed workpiece is considered for the next machiningpass.

 From process modeling to integrityanalysis:

Virfac® Crack is the first commercial software able toperform fully automated industrial three-dimensional fatigue crack propagationin complex assemblies with the eXtended Finite Element Method (XFEM). Cracksare easily introduced in complex models via level-set functions. Accuratestress intensity factors are readily computed and used to assess the structuralintegrity of the parts. Adequate level-set update functions and propagationlaws are then used to freely propagate cracks in the mesh, with automatichandling of the topological changes. Seldom manual interventions are neededwith Virfac®, thereby helping engineers make crucial decisions during designphases or during investigation of critical in-service failures. The crack module also plays a key role in the analysis of manufacturing defects.

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