Finite element methods and material processing technology

Abstract

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

Numerical Analysis of Intermediate Roll Shifting–Induced Rigidity Characteristics of UCM Cold Rolling Mill

“…An accurate description of metal flow in full detail, that is, capable of predicting the distribution of field variables in metal rolling processes is possible only with the introduction of the FEM into these analyses . Therefore, the FEM is now a powerful and reliable tool to simulate different rolling processes, including strip, sheet, billet, ring and tube rolling processes . The numerical modeling of rolling processes, especially the strip rolling process, using FEM has been the topic of much research .…”

“…[12] Therefore, the FEM is now a powerful and reliable tool to simulate different rolling processes, including strip, sheet, billet, ring and tube rolling processes. [17] The numerical modeling of rolling processes, especially the strip rolling process, using FEM has been the topic of much research. [18][19][20][21][22] Shang et al [23,24] developed a three-dimensional (3D) finite element(FE) model for a four-high hot rolling mill to improve the contour of continuously variable crown (CVC) work rolls and used this model to study the working characteristics of the CVC cyclical shifting mode for the mill of compact strip production.…”

Coupled Finite Element Flow Formulation

“…As a consequence, complex processes are now being simulated precisely without the need to take advantage of possible geometrical and material flow simplifications. A detailed survey of the state-of-the-art regarding numerical simulation of metal forming processes is given by Brännberg and Mackerle [3] and Mackerle [4,5].…”

“…Taking a general view to the bibliographic retrieval by Brännberg and Mackerle [3] and Mackerle [4,5] it appears that the finite element flow formulation is one of the most widespread numerical methodologies for the analysis of metal forming processes.…”

The contact and friction problem in the rolling process

“…Owing to the fact that this method, together with high-speed computers, is capable of predicting the detailed distribution of field variables, it is natural that nowadays the finite element method has been widely used for the analysis of metal forming processes in general and rolling processes in particular. Recently, Brannberg and Mackerle [4] made a literature survey on the application of the finite element method in the area of metal processing. They compiled a list of 1179 papers published from 1988 to 1993 on metal forming, nonmetal forming and powder metallurgy.…”