Finite element simulation of stretch forging using a mesh condensation method

In order to reduce the computation time of finite element simulations of stretch forging process,a mesh condensation method is presented and applied to a three-dimensional rigid-viscoplastic finite element program.In this method,a conventional mesh for the whole zone of a workpiece is condensed to a computational mesh for the active deformation zone.Two vital problems are solved,which are automatic construction of the computational mesh and treatment of interfaces between the deformation zone and the rigid zone.The mesh condensation method is compared with conventional finite element method by simulations of a six-bite stretch forging process.Some simulation results including forging load,temperature distribution and effective strain distribution are illustrated.The efficiency and accuracy of this method are verified.