Simulation of metal forming processes with finite element methods

Abstract

The traditional Lagrangian and Eulerian formulations in finite elements posses some inherent difficulties when used in simulation of metal-forming processes or general finite strain problems. A more general method of formulation, the Arbitrary Lagrangian–Eulerian (ALE), is developed to overcome such difficulties. A brief description of the ALE formulation is given with emphasis on the underlying differences between the developed formulation and existing ones in the literature. Some numerical algorithms for incorporating large deformation effect are presented. Typical metal-forming processes such as strip rolling, metal extrusion and punch forging are simulated using the ALE formulation and results are compared with available numerical and experimental ones. Special attention is given to numerical characteristics of the simulation, application of boundary condition and their effect on the results. Copyright © 1999 John Wiley & Sons, Ltd.