NUMERICAL-SIMULATION OF FORMING PROCESSES USING A COUPLED FLUID-FLOW AND HEAT-TRANSFER MODEL

Numerical simulation of forming processes is studied using the Navier-Stokes equations and the energy equation governing viscous, incompressible fluids. A review of various important aspects of forming processes is also reviewed for completeness. A penalty finite element model of the equations is developed. The finite element model is used to study the effectiveness of various constitutive models developed for metal forming and polymer processing. The element-by-element (EBE) data structure with efficient iterative solution methods is used to solve the large systems of equations that arise in the analysis of complex 3-D problems. Numerical results for problems representative of various forming processes (e.g. extrusion and solidification) are presented.