Abstract
Finite element models optimizing cold forged products have to incorporate the complete manufacturing pathway. Virtual process design as a method based on a multistep operation approach can describe interacting phenomena. Thus, inheritance effects like residual stress and damage evolution can be tracked throughout the processing chain. Besides the influence of the deformation direction (Bauschinger Effect) on material flow can be predicted. Using intermediate step optimization may also extend geometrical limits. Furthermore it may increase life time and improve material efficiency for a given component. The exploitation of these coupling effects may also form a basis for further product and process innovations.
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