Recent development and applications of three-dimensional finite element modeling in bulk forming processes

In this paper, the methodology of a finite element method (FEM)-based three -dimensional bulk forming modeling program is described using DEFORMTM as a n example. The FEM formulations are first reviewed, followed by discussions on the many considerations such as geometry representations, element selec tions, volume constancy, equation solvers and meshing methods. Since the up dated Lagrangian method is employed in the FEM calculation, an automated re meshing procedure must be used so as to continue the simulation when the me sh is severely distorted. Although DEFORMTM was originally developed for me tal forming simulation, due to its unique remeshing capability the use of t he code has been extended to other manufacturing fields, such as welding, m achining and glass forming. To demonstrate the methodology, some successful applications of the program to various forming processes such as ingot bre akdown, extrusion and orbital forging are presented in this paper. (C) 2001 Elsevier Science B.V. All rights reserved.