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.
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