Simulation of metal forming processes with finite element methods

The traditional Lagrangian and Eulerian formulations in Þnite elements posses some inherent di¦culties when used in simulation of metal-forming processes or general Þnite strain problems. A more general method of formulation, the Arbitrary LagrangianÐEulerian (ALE), is developed to overcome such di¦culties. A brief description of the ALE formulation is given with emphasis on the underlying di¤erences between the developed formulation and existing ones in the literature. Some numerical algorithms for incorporating large deformation e¤ect 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 e¤ect on the results. Copyright