Finite Element Calculation of Hot Forging with Continuous Remeshing

Abstract

One of the most crucial problems for the finite element modelling of non-stationary large plastic deformations in metal forming is the dramatic evolution of the mesh. In many industrial configurations the elements are so distorted after few incremental steps that accurate calculation is no longer possible, without remeshing. In this work, it is shown that a continuous remeshing procedure with adaptivity, compatible with the classical flow formulation approach, allows to perform very large deformations without any intervention of the operator. A practical example is analyzed for the forging of a gear tooth which demonstrates that the total process may be calculated completely automatically, saving more than 10 remeshing steps.