FEM simulation made by experts: we master the precise calculation of forming processes

At GMT, FEM simulation for your forming process is in the best hands

We have been specialized in FEM simulation of metal forming processes for many years and are your ideal partner for the FEM simulation of your metal forming process. In the metal industry, we can precisely map and calculate a wide variety of forming processes and heat treatments by using FEM simulation.

Within our service regarding the simulation of forming processes we support you individually and confidentiality with the realistic simulation of your process. Our in-depth expertise enables our clients to achieve outstanding simulation results. Furthermore, we transmit our specialist knowledge in individual training courses.
Open die forging

Hammer forging, mechanical press forging, radial forging, ring forging
Closed die forging

Hammer forging, mechanical press forging, closed die forging, flashless forging
Flat rolling

Slab, ingot, heavy plates, sheets
Sheet forming

Sheet rolling, deep drawing / cupping, cold rolling, bending, edging
Longitudinal rolling

Wire, bar, caliber, rail, profiles, reversing rolling, tube rolling (seamless pipes), straightening
Bulk cold forming process

Transverse rolling, thread rolling, gear rolling, ball, cross-wedge rolling, orbital forming, reducer rolling
Ring rolling and wheel rolling

Wheel tires, bearing rings
Cross rolling / skew rolling

Rod, tube, cross-roll piercing
Extrusion processes

Aluminum profiles, calculcation with extrusion dies
Heat treatment

Heating, tempering, hardening, cooling, annealing treatments

Simulation packages for forming processes and heat treatments

For the FEM simulation of your process, we use our unique FEM simulation packages QForm UK and QForm UK Extrusion. We also support you with the initial setup of your project in QForm UK. Hereby, we enable you to adapt your project to a wide variety of requirements on your own.
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What is FEM simulation?
FEM simulation is based on the application and visualization of numerical methods within the framework of the finite element method (i. e. FEM). Thus, process or material adaptations can be simulated in advance and checked for their feasibility or upcoming optimizations. In addition, practical tests can be saved by FEM simulation. The majority of all forming processes from the most diverse fields of forming technology and heat treatment processes can be calculated by applying many different factors - that is what makes FEM simulation particularly relevant.
Why is FEM simulation carried out in forming technology?
FEM simulation helps to realistically map many different metal forming processes. Thus, process or material adaptations can be made in advance and checked for their feasibility or upcoming optimizations. The finite element method simulation reduces the time and money needed for tests and thus leads to savings in terms of material and tool costs as well as development times.

The forming simulation of an industrial process within the framework of an FEM simulation can be used for practical evaluation and answers the following questions, for example:

• Is it possible to produce a new alloy with the existing facilities?
• Will the use of a new roll lead to a better result in terms of power and work needs or regarding the material properties?
• Which difficulties lie in new processing methods?

If errors have occurred in new products, these processes, which are difficult to measure or recognize in the course of the process, can be precisely retraced with FEM simulation. Taking into account the results from the FEM simulation, processes, material flows, temperature distributions, etc. inside the components can be better evaluated and optimized.

If there is heavy wear or even failure of the newly used tools, FEM simulation can be used to understand the influence of forming on the tool (loads, friction, temperatures, etc.); and the tools or the forming process can be adapted in such a way that the tools are stressed within the optimum range. To answer these questions, it is obligatory that the FEM simulation presents realistic results.
Where is FEM simulation in the field of metal forming used?
FEM simulation is used to analyze numerous forming processes and heat treatments and is a common tool in simulating forming technologies in the metalworking industry. When used correctly, FEM simulation results can reliably map processes and calculate the resulting product properties.

FEM simulation is used in manifold areas of the metalworking industry for process capacity planning, design of tools (die forging, for example), selection of suitable units / presses, checking of mold filling in die forging, checking of achievable microstructure with selected tools / forming conditions in a component (e. g. turbine blades) and error analysis. FEM simulation is also increasingly used in additive manufacturing.

Furthermore, heating and cooling processes can also be simulated realistically. Thus, it is also possible to simulate complete cycles of a heat treatment within the FEM simulation.
Why is GMT the ideal partner for FEM simulation?
Would you like to have an FEM simulation by order or as a service? GMT unites the core competences for a successful implementation of an FEM simulation. We do not just produce colorful pictures, but extensively evaluate the FEM results. It is an integral part of our activities based on our long-standing experience with various forming processes, extensive knowledge of materials and available material characteristics. Our service is rounded off by the practical work of our employees in industrial environment.

GMT has extensive know-how to use the FEM simulation package developed by QForm UK. We would be pleased to assess whether your question can be realistically mapped in an FEM simulation and would then take over the complete implementation and evaluation. By using the existing process and material knowledge as well as the material database MatILDa, the material characteristics can be entered precisely and realistic results can be achieved.
GMT’s experience in FEM simulation
GMT offers the FEM simulation of forming processes. We are experts in mapping many metal forming processes and in determining the material flow.

Forging processes / bulk forming process
• Open die forging, i. e. hammer forging, mechanical press forging, radial forging, ring forging of forged parts, forging of large shafts
• Die forging, i. e. hammer forging, mechanical press forging, closed die forging, flashless forging of forging pieces in the automotive or aerospace industry

Hot rolling processes
• Flat rolling of slab, ingot, heavy plates, sheets in hot forming and semi-hot forming
• Longitudinal rolling of wire, bar, caliber, rail, profiles, reversing rolling, tube rolling (seamless pipes), straightening in hot forming, semi-hot forming or cold rolling

• Sheet metal forming like sheet rolling, deep drawing / cupping, cold rolling, bending, edging with cold forming

• Bulk cold forming process like transverse rolling, thread rolling, gear rolling, ball, cross-wedge rolling, orbital forming, reducer rolling i. e. for the production of fasteners, screws, shaped parts

• Ring rolling and wheel rolling i. e. for the production of wheel tires or bearing rings

• Cross rolling or skew rolling of rod or tube, cross-roll piercing

• Extrusion processes of aluminum profiles, calculation with extrusion dies

• Various heat treatment processes, hardening processes like heating, tempering, hardening, cooling, annealing treatments

• Microstructure calculations like phase transformation, microstructure, grain size evolution, microstructural states, residual stresses, average grain sizes, static and dynamic recrystallization, grain size development, grain growth

GMT offers this service for simulation in the area of plastic forming. The tools are also taken into account with regard to the forming process. Other metal forming processes can be mapped using FEM simulation. Feel free to contact us!
Why is accurate, reliable forming simulation important?
By using exact, realistic FEM simulation, processes can be configured - without causing additional costs for tests. Therefore, reliable mapping of your process chain by FEM simulation is crucial.