Three Decades of Metal Forming Process Simulation

In the late 1970’s and early 1980’s, initial applications of process simulation were reported for metal forming applications using FEM.  The ALPID code was developed with funding from the US Air Force, and showed promise in a number of initial industrial applications.

Connecting the dots between early computer models and the shop floor required significant time and effort.  Over the years, many contributors pushed this technology to the point where most forge shops use simulation daily.  This technology has contributed directly to hundreds of millions of dollars in savings and faster process development cycles.  The benefits have been compounded with of improvements in computer technology. 

Today, process simulation spans multiple processes, with an eye on predicting the microstructure and mechanical properties of a finished part. 

The presentation will provide an overview of the advancements made in metal forming and heat treatment process simulation.  Additionally, a look at the future will be provided.  This is an ongoing success story worth telling.