Simulation of metal forming processes using finite elements

In this service, we carry out advanced numerical simulations of metal deformation processes:

• Cold forging
• Hot forging
• Rotary forging
• Cold stamping
• Hot stamping
• Tube rolling
• Tubes and sheet hydroforming

These processes are applied to different metal materials, such as steels, UHSS, 3rd generation steels, high strength aluminium, magnesium, titanium, etc.

Adding value to the service, we have specific software to stimulate the behaviour of metal deformation processes, such as FORGE NxT and Pam-Stamp and we also have experience with general purpose software, such as Abaqus and Ansys for process modelling.

Design and optimisation of metal forming processes

We offer a comprehensive approach to the development and improvement of metal forming processes, covering all key stages:

1. Operations prior to the forming process
   We carry out simulations of essential pre-process operations, such as sheet and bar cutting and heating processes (e.g. induction heating).
2. Design and optimisation of the forming process
   We design cold, hot and semi-hot metal forming processes (forging, stamping, rolling, etc.), using coupled thermo-mechanical models that ensure the precision and robustness of the process.
3. Incremental deformation processes
   We are experienced in simulating a wide range of incremental processes, such as rotary forging, flowforming, cross wedge rolling and ring rolling.
4. Design of preforms and tooling
   Numerical simulation enables preforms to be designed in accordance with the process and the final part, as well as the design of tooling. We also carry out thermo-mechanical analyses of the tools, including the calculation of pre-stressed tools to guarantee their durability and resistance under extreme conditions.
5. Microstructural evolution and heat treatments
   Numerical simulation enables the calculation of microstructural evolution and recrystallisation phenomena to be integrated in order to control and optimise material properties in forming simulations. Similarly, it is possible to simulate both surface and bulk heat treatments (austenitising, quenching, carburising, nitriding, induction hardening), ensuring that the components fulfil the required mechanical and durability specifications.

TECNALIA offers a unique proposal that combines numerical and experimental capabilities for the design, validation and optimisation of metal forming solutions. Our end-to-end approach enables our customers to approach process and metal component development with confidence, from virtual simulation to final physical validation.

We work in direct and close collaboration with our expert teams, ensuring continuous support at every stage of the project. We have specialists in material characterisation and advanced numerical simulation who can complement and enhance development, providing accurate and detailed analysis.

We also have an experimental cell in a semi-industrial environment, where we validate the technological solutions under representative real production conditions. This enables us to adjust and fine-tune the most significant parameters of the process before its final implementation.

To guarantee the quality and reliability of the results, we can carry out an exhaustivecharacterisation and validation of the mechanical and metallurgical properties of the materials and components manufactured. This includes mechanical testing, corrosion testing and metallographic studies to ensure compliance with the strictest requirements.

• Aeronautics and space
• Automotive industry
• Railway
• Metal transformation sector.