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We would like to take this opportunity to invite you to attend a new e-Learning masterclass entitled ‘A Tutorial Introduction to Forging Process Design Simulation’  and we are pleased to be able to offer you a FREE registration!


The course will consist of 3 sessions of 1 hour each and there will be tutorials set as homework.

The classes will take place at 12noon BST on Thursday, 11th, 18th and 25th September 2014.

Registration for the course is free of charge.

Places are limited and strictly on a first come, first serve basis!


Historically forging companies have made their designs based on experience acquired over many years, usually based upon trial and error: creating the design; manufacturing the tools; testing and then depending on the results, there may be many modifications to the design, final tool adjustments, new tests, etc.


Taking into account the high cost of tools for parts manufactured in many stages  the company that manufactures new products at the lowest cost, will generally be the one with the greatest profits. Finite Element Analysis-FEA software is therefore a helpful tool during the product and process design phase. Before any manufacture of the prototypes it is possible to predict the validity of certain designs and to predict stresses during forming, the tolling stages, maximum stress, zones of maximum wear and tear, breakage etc., and information of great use for toll and process optimization.


However, the use of numeric analysis software also supposes a certain difficulty. An analysis model which takes into account an important number of variables has to be created (material characterization, friction, thermal exchange, machines and tools used, speed of deformation, load application, damage criteria, wear, breakage etc) and this model, when deformation and stress is applied, must replicate reality. All this requires the use of complex calculation systems, with laborious data set up which also requires considerable calculation times. Paradoxically, in the industry designs have to be validated rapidly and therefore, in order to generate results rapidly using high speed calculations, it is convenient that the models should be as simple as possible.


This course provides an introduction to the design via computer simulation of forging processes via the use of tutorials, one for hot forging and one for cold forging. It attempts to indicate the design strategy that should be followed in order to achieve the best process and product design.


Course Details

The course will present some tutorials related to the design of a forging process via computer simulation. Use is made of real forging problems and attendees are provided with sufficient information to carry out their own forging simulations and explore different strategies. Their different processes and difficulties will be discussed and a process methodology for the same component will be presented.


The course is aimed at helping attendees in general forging design simulation and the stratgeuy of obtaining the best process design. It will not focus on any software in particular and will not help with the use of any software.

This will be a short introductory course and, if successful, a longer course with more tutorials will be created using the same methodology.


Who Should Attend

The target audience for this course would include process design engineers doing forging process simulations who wish to explore design processes or those who wish to refresh their previous work done in process design simulation.



Session 1

                  ° Course overview
                  ° Introduction to NAFEMS
                  ° Presentation of the design simulation process for a Radiator Valve
                  ° Presentation of forging simulation to be done by attendees: Fixed Gear

Session 2

                  ° Question & Answer session for simulation problem
                   ° Presentation of a methodology for the design simulation of the Fixed Gear
                   ° Presentation of forging simulation to be done by attendees: Tubular Component

Session 3

                  ° Question & Answer session for simulation problem
                   ° Presentation of a methodology for the design simulation of the Tubular Component
                   ° Course Summary


Course Process

This course will require use of forging simulation software enabling hot and cold forging.


E-learning courses are great alternatives and complements for continued education as they offer convenience and eliminate the need to travel. Strong effort is made for the course to be software neutral. However, examples from some of the more well-known and popular simulation cases and software will be used throughout the session.  Full notes are provided for the attendees.

Students will join the audio portion of the meetings by utilizing the VoIP (i.e. headset connected to the computer via headphone).



If you wish to register for this free e-Learning Masterclass, please simply contact Jo Davenport at NAFEMS at jo.davenport@nafems.org. We hope to welcome you on 11th September.