Implementing a high accuracy Multi-Mesh Method for incremental Bulk Metal Forming

The demand for the simulation of incremental bulk forming processes is high. However, the computation times for such simulations are still unsatisfactorily long and thus, their application is deterred. To accelerate the simulations, a multi-mesh algorithm was implemented in the Finite-Element simulation package PEP&LARSTRAN/Shape. This method uses a FE mesh which is fine in the deformation zone and coarse in the remaining areas. A second mesh, fine over the entire volume, is used to store computed values and to minimize the loss of accuracy. The method was tested on an open die forging process and adapted for ring rolling. This paper describes the latest further developments of the method in [1], for instance tool kinematics, remeshing and data transfer and compares its results to conventional models, thereby showing its performance and accuracy.