Cost effective implementation of forging simulation

The development of forging simulation software has initiated the problem of its cost-effective implementation in a forging company. This paper presents an approach to this issue based on experience gained through the development of the software, and long term collaboration with the forging industry in everyday practical work. The effectiveness is based on advanced user friendliness of the simulation software and its application to wide range of problems. These include: the precise control of material flow during forming, material savings, increasing tool life by means of optimisation of pre-stressed dies, and the development of profiled dies that compensate for the elastic deformation of the tooling set. Special attention is paid to the prediction of forging defects and finding ways to eliminate them. Different aspects of simulation advantages are highlighted.