APPLICATION OF THE 2D FINITE-ELEMENT METHOD TO SIMULATION OF VARIOUS FORMING PROCESSES

In recent years, computer-aided engineering (CAE) techniques have been applied increasingly with great success in metal forming research, as well as in the cold and hot forming industry. Initially, computer simulation of metal flow and detailed stress analysis of dies were conducted by forging companies that supply the aerospace industry. During the last several years, however, the two-dimensional computer code DEFORM, developed by Battelle Columbus Laboratories, has been fully commercialized. This code is now also used extensively by non-aerospace forgers for the investigation of die fill, defect analysis and prevention, as well as for the prediction of part properties. At the Engineering Research Center for Net Shape Manufacturing (ERC/NSM), DEFORM is one of the available computer-aided tools used in metal forming research and for educational purposes. This paper summarizes some of the industrially relevant research results obtained with DEFORM, including the prediction of flow-induced defects, precision forging of aluminum alloys, investigation of a suck-in type extrusion defect, forging of bevel gears, stress analysis of forging dies, and development of a new test to evaluate lubrication in cold forging.