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Metal Forming Simulations (FEA)

 

The most time consuming and expensive part of the forging process is the initial setup of the press. Especially for the new and special parts, a trial-error procedure is carried out on the press in order to solve unanticipated problems like; die underfilling, improper material flow or catastrophic tool failure, until a stable production condition is achieved.

 

We are using state-of-art finite element analysis (FEA) programs to simulate the forming process in order to predict the potential problems and fine tune the design parameters to eliminate any possible forming and tool issues.

 

Parameters which are analyzed in the FE simulations are:

 

  • Material flow and die filling
  • Forming forces
  • Forces acting on the tool components
  • Stress and strain distribution on the workpiece
  • Die wear
  • Residual stresses
  • Ductile damage on the workpiece

  • Results of the simulations are delivered as an engineering report with animations.
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