INPRO Innovationsgesellschaft mbH Berlin

Simulation-supported forecasts are now a central component of manufacturing planning, especially for the design of forming processes in stamping plants. Modern simulation tools are key to ensuring that forming tools can be designed faster and cheaper and can be qualified for volume production.

The numerical simulation of metal forming became a focus of joint innovation work at INPRO by the end of the 1980s. The fundamental feasibility of simulation-based prediction of thermoforming processes could be demonstrated as early as 1989.

Significant algorithms in the fields of kinematics/elements, contact/friction and material modelling were developed and implemented for the first time. The adaptations carried out to the finite element method used for sheet metal forming were a pioneering effort on the road to industrial forming simulation.

With the success of this initial phase, user confidence increased and with it, market demand. In cooperation with the stakeholders involved, a software industry was created, which today successfully provides solutions on the market for forming simulations. Leading companies in this area, for example AutoForm and ESI are important INPRO partners today.

Given its introduction across the board, metal forming simulation has become a standard process in production planning. The quality of stamping parts was improved and tool costs clearly reduced, sometimes even cut in half. The technologies to improve the quality of prediction is carried out continuously. 

Currently, INPRO is working with many partners to further increase the predictive quality of simulation models. An interim result is now the addition of springback compensation for high-strength steels. Our partners Daimler, ThyssenKrupp and Volkswagen are intensively focusing in this development work. This enables them to adjust internal procedures to new opportunities early on and to continually improve the capabilities of their planning processes.