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State of Development and Benefit from FEM-Simulation of Bulk Forming Processes.In the last years numerical simulation of forming processes with the finite element method (FEM) has become more and more established in industrial use. The spreading of commercial FEM programs is one reason for this development. Increased computer power and improved algorithms made it possible to simulate forming processes for parts with complex shapes manufactured by extrusion or drop torging, whereby material flow, temperature and strain distribution in the workpiece are calculated.Further important information about microstructure and residual stresses can be obtained by coupling the simulations with grain and heat treatment modules. By damage models Iocations in the workpiece with high cracking potential as well as the lifetime of the tools can be predicted. Therefore, simulation can help to reduce significantly development time and costs for new products. The present paper shows the current state of the art of numerical simulation and provides an overview of the commercial simulation programs.

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