Simulation of three-dimensional bulk forming processes by finite element flow formulation

This paper focuses from the fundamentals of finite element flow formulation to the main aspects of computer implementation and modelling of three-dimensional bulk forming processes. Fundamental research and development is based on a comprehensive analysis of a wide range of theoretical and computational subjects such as selection of elements, solution procedures, contact algorithms, and meshing and remeshing procedures. We also focus on elastic analysis of tooling and a simple algorithm is proposed for transferring the load across the die-workpiece contact interface. The overall study is supported by several specially designed, cold forming experimental parts that were manufactured under laboratory-controlled conditions. Comparisons between theoretical predictions and experimental results comprise a wide range of topics such as material flow, geometry, forming load and strain distribution.