Localized remeshing techniques for three-dimensional metal forming simulations with linear tetrahedral elements

The localized remeshing technique for three-dimensional metal forming simulations is proposed based on a mixed finite element formulation with linear tetrahedral elements in the present study. The numerical algorithm to generate linear tetrahedral elements is developed for finite element analyses using the advancing front technique with local optimization method which keeps the advancing fronts smooth. The surface mesh generation using mesh manipulations of the boundary elements of the old mesh system was made to improve mesh quality of the boundary surface elements, resulting in reduction of volume change in forming simulations. The mesh quality generated was compared with that obtained from the commercial CAD package for the complex geometry like lumbar. The simulation results of backward extrusion and bevel gear and spider forgings indicate that the currently developed simulation technique with the localized remeshing can be used effectively to simulate the three-dimensional forming processes with a reduced computation time