Simulation of bulk metal forming process chains

At Fraunhofer IWU, the potential of simulation is leveraged to holistically analyze complete bulk metal forming process chains—from billet cutting and heating through the individual forming stages to final thermal post‑treatment. Microstructural aspects can be integrated into the evaluation, as can the interactions between the forming process and the forming machine.

Key focus areas of our simulation studies include:

• Feasibility studies for new products
• Design and optimization of mass pre‑distribution to reduce raw material consumption
• Determination of thermally stable operating states of tools within process stages
• Reduction of process steps to lower energy consumption and costs
• Creation of material hybrids for lightweight design
• Reduction or avoidance of machining post‑processing
• Functional integration through the consolidation of components

In addition to these simulation studies, we support and advise our customers in decision‑making processes related to the introduction of new forming technologies and process chains.

For highly realistic simulation results, accurate material property data is essential. For new materials, we therefore determine hot and cold flow curves, which are directly incorporated into the simulations. For the simulation of bulk metal forming process chains, we primarily use Forge and Simufact Forming.

The results of our simulation studies are reflected in:

• Adaptation of component geometries to individual forming steps in order to minimize tool loads and wear
• Tool design and engineering
• Design of process steps and adjustment of process parameters
• Optimization of existing process chains
• Development and evaluation of new process chains