3D FEM simulation of multi-stage forging process using solid modeling of forging tools

The development of the FEM simulation of metal forming is reviewed and the key techniques of the 3D FEM simulation of multi-stage forging processes ar e discussed. A CAD/CAE integration system has been developed to simulate in dustrial multi-stage metal forming processes. By using solid modeling of th e forging tools, a complicated multi-stage forging process is simulated to analyze the 3D metal flow of the industrial part, a cross-shaft. The simula tion results show good agreement with the practical part. (C) 1999 Elsevier Science S.A. All rights reserved.