FE simulation of forming processes and cutting processes

Representing, understanding and optimizing innovative processes

Numerical simulation is an indispensable tool of analysis in sheet metal processing. It opens up the possibility to evaluate at an early stage of tool development how innovative technologies can be implemented. Furthermore it enables the determination of optimum parameters for processes and geometries and to deepen the overall process knowledge.

In order to develop new products or to enhance existing processes of sheet metal forming, it is essential to predict and optimize quality characteristics such as thinning or shape accuracy of the components.

Temperature and other influencing factors play a significant role in numerous innovative applications, which may lead to considerably more extensive and sophisticated numerical models. However, such enhanced numerical models also grant the developer access to the complex interactions of physical and technological factors involved in the examined forming process.

Feasibility studies and design of deep drawing operations

  • Design of tube drawing
  • Design of magnesium door

Analysis of hot forming

  • Process analysis of press hardening
  • Cooling of the tool via cooling channels along the contour


  • Hydroforming – hot forming of crash box
  • Colorado cross member
  • Assembly of ribbed radiators

Simulation of cyclic thermal processes

  • Investigation of cyclic thermal loads in tempered tools
  • Cyclic analysis of a press hardening process

Simulation of cutting processes

  • Punching of tubes
  • Helical gear
  • High speed impact cutting

  • Extensive process analysis
  • Development of feasibility analyses for forming processes
  • Determination of optimum process parameters
  • Investigations on mechanical and thermal tool loads

Development of process chains

  • Investigation of process chains
  • Process optimization
  • Contribution to development of manufacturing concepts
  • Fundamentals for planning and technological dimensioning of processes, tools and machines

Development and evaluation of forming strategies

  • Feasibility studies
  • Analysis of variants in technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation

Quality assurance

  • Quality assurance regarding component properties (dimensional stability, mechanical properties) 

Computer technology

  • Modern work stations (Windows)
  • Computing cluster (LINUX)


  • AutoForm
  • LS-Dyna
  • Abaqus
  • PamStamp
  • Ansa