Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Optimization of Tool and Process Design for the Cold Forging of Net-Shape Parts by Simulation

Project Status: finished


Within this project, a comprehensive approach was developed to consider interactions between the cold forging process, the tool and the machine during the tool and process layout by simulation. The approach comprises an efficient determination of the deflection characteristic of press and tooling system and its subsequent modeling in combination with the FE simulation of a cold forging process. Based on a set of simulations with this combined FE model, an analytic process model can be calculated. It permits an optimization of the values of influencing parameters to achieve high workpiece accuracy. The required number of simulations for the process modeling can considerably be reduced by applying knowledge on the process behavior. The approach was supplemented by using the process model for the estimation of scatter and uncertainties of the workpiece dimensions depending on the ones of the influencing parameters.

Tooling system for lateral extrusion on a force-controlled press (a.); Force-deflection curves (b.)

Research Groups



    • Kroiß, T.:
      Process Modeling in Cold Forging Considering Process Machine Interactions and Scatter of Influencing Factors.
      In: Hora, P. (Edtr.): Proc. 4th Form. Technol. Forum, Institute of Virtual Manufacturing, ETH Zurich, ISBN: 978-3-909386-48-2, 2011, pp. 129-134


    • Kroiß, T.; Engel, U.; Merklein, M.:
      Process Modeling In Cold Forging Considering The Process-Tool-Machine Interactions.
      In: Barlat, F.; Moon, Y. H.; Lee, M.-G. (Edtrs.): Proc. of the 10th Int. Conf. on Numerical Methods in Industrial Forming Processes; AIP Conference Proceedings 1252, American Institute of Physics, 2010, pp. 312-319

    • Kroiß, T.; Engel, U.; Merklein, M.:
      Modeling of the Behavior of a Cold Forging Process Considering the Deflection of Tooling System and Press.
      In: (Edtr.): Proc. 2nd Int. Conf. on Process Machine Interactions (PMI), ISBN: 978-0-9866331-0-2, 2010, published on CD

    • Kroiß, T.; Engel, U.; Merklein, M.:
      Simulation-Based Determination of Deflection Characteristic of Tooling System and its Modeling in FE Simulation of Cold Forging Process.
      In: K. Mori et al. (Edtr.): steel research international (special edition Metal Forming 2010), Wiley-VCH Verlag GmbH & Co. KGaA, 2010, pp. 318-321

    • Groenbaek, J.; Engel, U.; Hinsel, C.; Kroiß, T.; Meidert, M.; Neher, R.; Räuchle, F.; Schrader, T.:
      Tooling Solutions for Challenges in Cold Forging.
      In: Groche, P. (Edtr.): 43rd ICFG Plenary Meeting 2010, Institut für Fertigungsforschung e. V., 2010, pp. 112-130


    • Kroiß, T.; Engel, U.:
      FE-Based Modeling of Interactions Between Cold Forging Process, Tooling System and Force Controlled Press.
      In: Gantar, G. (Edtr.): ICIT&MPT 2009, Proc. of the 7th Int. Conf. on Industrial Tools and Material Processing Technologies, Oktober 4-7, Ljubljana, Slovenia, TECOS, 2009, pp. 293-300


    • Kroiß, T.; Völkl, R.; Engel, U.; Geiger, M.:
      Modeling of Process-Tool-Machine Interactions in Cold Forging.
      In: Denkena, B. (Edtr.): Proc. 1st Int. Conf. on Process Machine Interactions (PMI), PZH, 2008, pp. 175-182

    • Kroiß, T.; Engel, U.; Völkl, R.; Geiger, M.:
      Process-machine interactions in cold forging – calculation of press / tooling stiffness and its integration into FE process simulation.
      In: Yang, D.Y. (Edtr.): Proc. of the 9th International Conference on Technology of Plasticity (ICTP), 2008, pp. 1735-40


    • Kroiß, T.; Völkl, R.; Engel, U.:
      Berechnung der Wechselwirkungen zwischen Umformmaschine und -prozess auf Basis der Integration eines Pressenmodells in die FE-Fließpresssimulation.
      In: DWM (Edtr.): Proc.12th Dresdner Werkzeugmaschinen-Fachseminar, 2007, published

    Letztes Update: 24.11.2011