Capabilities of numerical simulation support for defect investigations in die forgings

Capabilities of numerical simulation support for defect investigations in die forgings

Marek Hawryluk1, Sławomir Polak1, Łukasz Dudkiewicz1,2, Jan Marzec1, Magdalena Jabłońska3, Maciej Suliga4, Roger Tkocz5, Grzegorz Korpala6

1Wroclaw University of Science and Technology, Department of Metal Forming, Welding and Metrology, Wroclaw, Poland.

2Schraner Polska sp. z o.o., Łęczyca, Poland.

3The Silesian Technical University, Department of Material Technologies, Gliwice, Poland.

4Czestochowa University of Technology, Faculty of Production Engineering and Materials Technology, Czestochowa, Poland.

5MAHLE Behr Poland, Ostrów Wielkopolski, Poland.

6Institut für Metallformung, TU Bergakademie Freiberg, Freiberg, Germany.



The article concerns the use of the results of numerical simulations, primarily for the detection of defects in forged products identified at various stages, along with the analysis of the geometry of forgings and the way in which the material flows in tools. The work presents the results of measurements and analyses using numerical modelling based on computational packages dedicated to forging processes such as: QForm, Forge, etc., which are equipped with special functions that significantly facilitate analyses by both technicians and designers. These functions include: contact of the deformed material with the tool, flow line distribution, “trap” or “fold” functions for detecting forging defects, as well as other technological parameters and physical sizes, which are crucial in the case of a comprehensive analysis of the industrial die forging process. The novelty of the work is the presentation of the possibility of simultaneously combining many different non-destructive techniques and methods, e.g. results of FE simulations with 3D reverse scanning, minimizing interference in the industrial process. The research carried out allows for the thorough and rapid analysis of the correctness of the deformation of the forging material for selected forging processes, along with the presentation of methods for their prevention and solving various technological and engineering problems, which is particularly important in terms of reliability and production efficiency.

Cite as:

Hawryluk, M., Polak, S., Dudkiewicz, Ł., Marzec, J., Jabłońska, M., Suliga, M., Tkocz, R., Korpala, G. (2024). Capabilities of numerical simulation support for defect investigations in die forgings. Computer Methods in Materials Science, 24(1), – .

Article (PDF):

Accepted Manuscript – final pdf version coming soon


Forging defects, FE modelling, Hot forging process, Special function in FEM packages