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
Slab, ingot, heavy plates, sheets
Sheet rolling, deep drawing / cupping, cold rolling, bending, edging
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
Aluminum profiles, calculcation with extrusion dies
Heating, tempering, hardening, cooling, annealing treatments
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 forming 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 deformation 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, forming 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 / deformation 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?
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.
Would you like to have an FEM simulation by order or as a service? 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. Your FEM simulation is in the best hands at GMT.
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 simulation for extrusion processes of aluminum profiles, calculation with extrusion dies
• Various heat treatment processes, hardening processes like heating, tempering, hardening, cooling, annealing treatments
• Microstructure calculations
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.