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New Challenges in Numerical Simulation of Forging Processes: Multiscale and Multiphysics Approaches

New Challenges in Numerical Simulation of Forging Processes: 

FEM Forging Project (more information) 

Industry must demonstrate the ability to develop, process and join increasingly diverse and complex materials, in a well-controlled manner and in all economic sectors: aerospace, nuclear, defense, energy ... To meet these requirements, processes evolve and new appear. Another demand of the industry is to work across the entire range of manufacturing steps or life cycle of products: from the development of the material and its forming processes to recycling without forget the steps of heat treatment, assembly and usage properties. This serves two purposes:

  • better control of the material flow and energy and have a global vision of the transformation of materials,
  • But above all, take into account the effect of the inheritance of properties, structures, defects from upstream to downstream processes.

Multi-physics and multi-scale modeling is a key driver in such actions. We will give examples of numerical challenges that have missions to meet these industry needs. In metal forming industry, elimination of internal defects is a prerequisite to avoid catastrophic failure of part. Advanced numerical methods such as level set methods to describe the interface followed within a framework of finite element formulations can be used to model the germination, growth and void closure in the ductile damage. The same level set method can also be used to simulate grain growth and polycrystalline microstructures mobile interfaces. Finally, heat treatment like heating (including induction heating) and quenching are also of major importance in the workpiece life and must be simulated accurately by coupled modeling of several fields of physics: mechanics, heat, electromagnetism, chemistry, metallurgy.


David Quinn, NAFEMS

An Introduction to FEM Forging
Dr Gino Duffett, NAFEMS

New Challenges in Numerical Simulation of Forging Processes: Multiscale and Multiphysics Approaches
Professor Elisabeth Massoni, CEMEF

Q & A Session


This webinar is the second 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. 

Who Should Attend?

The target audience for 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 Elisabeth Massoni

Elisabeth Massoni is the director of CEMEF (Materials Forming Center). CEMEF belongs to MINES ParisTech institution and is located in Sophia-Antipolis in the south of France. Research is multidisciplinary at CEMEF, from fundamental research to applications. Based on fundamental studies, the centre’s research activities are focused on physical and mechanical understanding of the principal aspects of materials processing and forming. Numerical codes on metal and polymer forming are then developed in the laboratory and industrialised by the software company Transvalor. The specificity of these codes is the different level of coupling: multi-scale, multi-materials and multi-physics. Around 160 people are working at CEMEF, about 60 permanent staff and 70 doctoral students.

The field of expertise of Elisabeth Massoni is on numerical simulation of metal forming processes (thin sheet forming, flow forming, hemming,..) and heat treatment. It concerns mainly the development of large strain behaviour, plastic anisotropy, nonlinear isotropic and kinematics models. These activities are mainly conducted through Phd research projects(around 25) in close collaboration with the industry in different economic sectors (automotive, aeronautics,…).

Elisabeth Massoni is also member of the board of CSMA(French Computational Structural Mechanics Association), ESAFORM (European Association of Material Forming), Pégase French Aeronautices cluster. She is also president of a SF2M (French Society on Metallurgy and Materials)Commission on Thin Sheet Metal Forming and Super plasticity.

Dr 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.