Computer simulation of the deep extrusion of a thin-walled cup using the thermo-mechanically coupled elasto-plastic FEM

During bulk metal forming processes, the workpieces are usually subjected t o extremely large deformation with change of temperature. In this paper, a thermo-mechanically coupled elasto-plastic FEM system has been developed ba sed on ANSYS software and the finite strain theory. Using this system, the deep warm extrusion of a thin-walled cup has been simulated. The basic para meters for process development and die design such as the metal flow and th e distribution of stresses, strains and temperature in the die and the work piece, taking into account conduction, convection, radiation and plastic wo rk, the loading-time curve, and the cause of failure on the punch, are obta ined and analyzed. Industrial experiments have been carried out. The comput er simulation results are in good agreement with the experimental results. (C) 2000 Elsevier Science S.A. All rights reserved.