Abstract
A new upper-bound elemental method is proposed to improve the ineffectiveness of the upper bound elemental technique (UBET) for solving forging problems that are geometrically complex or need a forming simulation for predicting the profile of the free boundary. This method combines the advantages of stream function and the finite element method (FEM). Specifically, the curve fitting property of FEM and the fluid incompressibility of the stream function. The formulated optimal design problems with constrained conditions are solved by the flexible tolerance method. Three forming problems, ring upsetting, closed-die, and backward-extrusion forging are used to illustrate this method: the results of ring upsetting show a good ability of simulating the forming profile of the free boundary, the closed-die forging results show lower upper-bound solutions than UBET and backward-extrusion forging shows the flexible curve fitting property for a complex geometric boundary.
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