The most time consuming and expensive part of the forging process is the initial setup of the press. Especially for the new and special parts, a trial-error procedure is carried out on the press in order to solve unanticipated problems like; die under-filling, improper material flow or tool failure, until a stable production condition is achieved.

We are using state-of-art finite element analysis (FEA) simulation programs to analyse forming process in order to predict potential problems and optimize process design to eliminate any possible forming issues.

Parameters which are analysed in the FE simulations are:

• Material flow and die filling
• Forming forces
• Forces acting on the tool components
• Stress and strain distribution on the workpiece
• Die wear
• Residual stresses
• Ductile damage on the workpiece