Simulation of media-based forming processes

Finite element (FE) simulation is a core capability for the effective design and optimization of a wide range of forming processes. At Fraunhofer IWU, FE simulation has been applied with proven expertise for many years, particularly in the field of media‑based forming technologies. Our competencies extend from the simulation of small‑scale forming demonstrators to the process design of internally high‑pressure‑formed components for diverse automotive applications, and further to the development and optimization of high‑pressure sheet metal forming processes for bipolar plates.

The process‑specific simulation of temperature‑controlled, strain‑rate‑dependent, and multi‑stage forming operations is part of our daily work. In addition, we possess recognized expertise in special forming processes, such as the simulation of superplastic tube forming using active media. These processes often require advanced material models, whose parameter identification we provide comprehensively in‑house through dedicated fundamental material testing.

By continuously benchmarking our simulations against experimental investigations and small‑series demonstrators, we have established a broad and reliable knowledge base. The simulation models we use are systematically validated both within publicly funded research projects and industrial development programs.

Our service portfolio

• Simulation‑based process modeling of all media‑based forming technologies
• Technology‑oriented material testing and material model development
• Process optimization
• Simulation of temperature‑controlled and strain‑rate‑dependent forming processes
• Modeling of special forming technologies
• Model validation