Non-linear finite-element analyis on microcomputers for metal forging

Abstract

In recent years microcomputers have become more powerful and for some purposes are now able to compete with minis and mainframe computers. It is now possible to implement a wide variety of CAD packages and linear finite-element stress analysis programmes on microcomputers, but the solution of non-linear problems - for example, forging - is more complex. This paper shows that a microcomputer can, nevertheless, be used for the analysis of a bulk metal forming process where there are both geometric and material non-linearities. The programs give reliable estimates of metal flow, grid distortions, stress, and strain distributions in the workpiece, as well as the forming force. An elastic-plastic finite-element method is used, with SSS-Fortran as the computing language. The results of such simulations can be used in-house to form the basis of improved forging die design, and, hence, a better final product, without the need for much of the expensive and time-consuming experimental trials currently practiced in industry.