Benchmark of a forging process with a hammer: comparison between fem simulation results and real part shapes using 3D digitising scanner

As 3D scanners and numerical simulation are now mature, we have made a benchmark by comparing simulation results with real forged parts. We did consider the complete forging process of a cylindrical part using hammer from the billet to the final part. This process has been simulated using a thermo-elasto-viscoplastic constitutive equation including the ductile damage with the implemented with the help of VUMAT subroutine provided by ABAQUS software. Before and after each step, the forged part is scanned and compared with the result of the FEM simulation in order to tune some of the process numerical simulation parameters.