Simulation of metal forming processes with finite element methods

The traditional Lagrangian and Eulerian formulations in finite elements pos ses some inherent difficulties when used in simulation of metal-forming pro cesses or general finite strain problems. A more general method of formulat ion, the Arbitrary Lagrangian-Eulerian (ALE), is developed to overcome such difficulties. A brief description of the ALE formulation is given with emp hasis on the underlying differences between the developed formulation and e xisting ones in the literature. Some numerical algorithms for incorporating large deformation effect are presented. Typical metal-forming processes su ch as strip rolling, metal extrusion and punch forging are simulated using the ALE formulation and results are compared with available numerical and e xperimental ones. Special attention is given to numerical characteristics o f the simulation, application of boundary condition and their effect on the results. Copyright (C) 1999 John Wiley & Sons, Ltd.