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Developments in Forging Simulation

Developments in Forging Simulation

FEM Forging Project (more information)



This FREE Webinar introduces the production of forged metallic parts is one of the oldest manufacturing methods known to mankind and has developed from hand operations to the automated industry of the modern world.Contrary to popular belief significant advances continue to be made in this field with, for example, the achievable tolerances in precision forging reducing from 500 to 50mm in the last25 years while accompanied by cost reduction. This has been achieved through the development and implementation of leading edge technologies in new press designs, tooling and flexible automation to meet the continuing demands for higher productivity and lower cost while still improving process capability.Greater understanding of the response of materials to processing has also led to improved properties and consistency in the manufactured products. Many of these developments have been facilitated by the use of process simulation such that finite element based modelling tools, for example, are now a standard part of the forging design process.


These software tools are routinely used to predict the stresses, strains and temperatures that are developed during forging and the presentation will examine the developments in simulation which allow the prediction of microstructure and properties. These approaches have the potential for the manufacture of microstructurally controlled semi-finished product which can then be used to produce finished precision parts with predicted mechanical performance. A natural extension of this approach is to use the predicted distributions in material microstructure, e.g.grain size or precipitate volume fraction, to provide the scatter in mechanical properties. The potential benefit of this approach to the prediction of component life will be presented.



Tim Morris, NAFEMS
An Introduction to FEM Forging
Dr Gino Duffett, NAFEMS
Developments in Forging Simulation
Professor Jeffery Brooks, University of Birmingham
Q & A Session



This webinar is the first of two sponsored by the FEM Forging project, which is funded by the EU under the Leonardo initiative. The project is focussed on the development of continuous training of specialists on design and optimization of hot, warm and cold FORGING processes using FEM simulation technologies. Further information is available on the project website at


this webinar are managers, engineers, analysts who wish to understand the capabilities and potential benefits of using FEA simulation in the Forging industry.


Webinar Presenters

Professor Jeffery W Brooks


Hanson Professor Industrial Metallurgy – University of Birmingham 2013
Professor Manufacturing, Director AFRC - Strathclyde University 2009
Technical Manager – Engine Materials & Lifing – QinetiQ 2004 to 2009
Technology Chief – Aero Engine Design and Lifing – QinetiQ 2001
Fellow of the IoMMM -2000 and DERA Fellow – 2001
Principal Scientist – Process modelling - DERA 1998
Chief Metallurgist – DONCASTERS plc - 1992
Manager Metallography – INCO Engineered Products Ltd


Current activity and discipline
Professor Brooks is a recognised authority on the microstructure, mechanical properties and the manufacturing process routes of the materials used in aerospace components. He has developed finite element modelling techniques for stress analysis and manufacturing process simulation that are applied in industry and academia. He has an established track record in initiating, growing and managing research groups in both industry and research and technology organisations. In his current role as Director of thePartnership for Research in Simulation of Manufacturing and Materials (PRISM2)at the University of Birmingham he is responsible for the strategic direction of the centre and delivery of the research portfolio. The aim of the partnership is to develop, validate and implement multi-scale modelling approaches for the simulation of materials behaviour, component performance and manufacturing process prediction.



Background and previous career
Maintaining the structural integrity of aerospace components requires reproducible production methods to provide consistent properties and low levels of defects. This is especially true for rotating parts in aero gas turbine engines and particularly so for the turbine discs where an uncontained failure could result in the loss of the aircraft. Prof. Brooks has initiated and led research for the provision of support services and advice on the manufacture and structural integrity of the propulsion systems for civil aircraft and in all the major RAF and RN platforms (including Typhoon, Tornado,Harrier, Merlin, Chinook).


His early career in manufacturing industry concentrated on developing modelling techniques for the simulation of the complex interaction between plastic deformation and thermal history that occurs in both industrial metal working processes and in-service components. This has allowed the prediction of microstructural development, the mechanical properties and performance of the manufactured products. Later work on manufacturing aerospace materials and component lifing has led to many collaborative projects with industries including Rolls-Royce plc, The Boeing Company and their tier one suppliers. He has published many peer-reviewed papers and regularly gives invited keynote presentations at international conferences and meetings.



Principal accomplishments


  • Established the Advanced Forming Research Centre (AFRC) as a significant research entity with 70 staff and attracted £30M from the High Value Manufacturing Catapult.
  • Drafted the lifing and risk assessment content for the MoD Propulsion Integrity Policy.
  • Developed a microstructural model for the process optimisation of titanium alloysemi-finished product. This is now used by manufacturing industry in both the UK and the US.
  • Initiated and led a materials modelling group and achieved £4M turnover in five years.
  • Developed isothermal forging technology which led to the installation of a UK capability for the manufacture of gas turbine discs for the EJ200 Typhoon engine.
  • Developed a finite element based model for the production of forgings with controlled structures and properties.
  • Developed a bolster design for precision forging which is now the UK industry standard.

Dr Gino Duffett BSc, PhD, MADr Gino Duffett
BSc, PhD, MA


Gino Duffett has over 30 years of experience in CAE software creation, training and industrial implementation and usage on an international level in various sectors, mostly automotive and renewable energy. Currently a Technical CAE Manager focussing on simulation driven design and automatic optimization.



Over his career Gino has taught numerical modelling up to university level, developed commercial courses and provided training for software users and Masters programmes on aspects such as metal forming, simulation process methodologies and optimization and has provided courses at Business schools on ERP and multi-cultural management.