Recent development and applications of three-dimensional finite element modeling in bulk forming processes

In this paper, the methodology of a finite element method (FEM)-based three-dimensional bulk forming modeling program is described using DEFORM™ as an example. The FEM formulations are first reviewed, followed by discussions on the many considerations such as geometry representations, element selections, volume constancy, equation solvers and meshing methods. Since the updated Lagrangian method is employed in the FEM calculation, an automated remeshing procedure must be used so as to continue the simulation when the mesh is severely distorted. Although DEFORM™ was originally developed for metal forming simulation, due to its unique remeshing capability the use of the code has been extended to other manufacturing fields, such as welding, machining and glass forming. To demonstrate the methodology, some successful applications of the program to various forming processes such as ingot breakdown, extrusion and orbital forging are presented in this paper.