Finite element simulation of industrial forming processes using automatic 2D mesh generation and remeshing

The framework used in this work is based on the incremental flow formulations, where elastic strains are assumed to be negligible compared to plastic strains. To handle the frictional contact between the die and deforming material with master and slave surfaces, Perturbed Lagrangian formulation with a new one pass algorithm has been implemented. The frame work is sufficiently general to solve wide range of metal forming problems. During simulation of metal forming processes where large plastic deformations are possible severe mesh distortions occurs after few incremental steps. So, an automatic mesh generation with remeshing capabilities is essential to carry out finite element simulation of complex metal forming processes effectively. Remeshing essentially involves transfer of state variables from old (distorted) mesh to the new mesh. A real life metal forming problem has been simulated and the results are verified by capturing accurately the folding defect in the manufacturing of a forged component.