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New contact boundary modelling is achieved with a basic set of 2 and 3 dimension contact primitives. Contact constraints are originally introduced in the variational equations and associated Newton—Raphson scheme via an external penalty formulation using primitive equations. Consequently, penalty part of external load vector and tangent stiffness matrices are developed for all contact primitives. In this way, contact prescribed boundary displacements are also taken into account. Contact treatment is then completed with Newton—Raphson elements for elastic and plastic regularized friction constitutive models. In this paper, the process is extended to elastoplastic models. Finally, we propose a self acting procedure with contact algorithms (interiority, sliding and contact loss) and related subroutines for implementation in finite element framework. We illustrate these developments by means of two‐dimensional open die forging and three‐dimensional plate coining typical benchmarks with reference to bulk elastoplastic and viscoplastic constitutive models.

Inside the finite element framework of LAGAMINE code, the contact conditions are introduced with specific two‐node interface elements and four‐node quadrangular elements or four‐node one point quadrature elements. A non‐associated flow rule is involved for sliding unilateral contact modelling. Two methods of penalty factor computations in the penalty contact algorithms are presented. These methods are then used for contact modelling of two isothermal examples: axisymmetric tube expansion and asymmetric slab bending, the material bulk constitutive equation being isotropic and elasto‐plastic.

Microstructure void volume fraction is taken into account in finite element models developed for large strain elastoplastic problems. Void nucleation rate is related to matrix effective strain rate, void growth to material strain rate and associated elastoplastic potential available for porous material, void coalescence to matrix effective strain rate. The related radial return algorithm is described. Three types of computations are proposed: first, axisymmetric Q4 element traction are given as validation example; second, collar cylinder compression are computed as reference example; third, bulk forming are analysed as large strain specific example. Void volume fraction and hydrostatic stress are mainly discussed according to microvoids nucleation, growth and coalescence. Finally, the main interests of those computations are enhanced.

To study the nature of scuffing in boundary lubricated sliding contacts with subsurface plastic deformation, as it occurs in plastic deformation processing.

Low speed oblique plastic impact testing (LOSOPIT) has been conducted on copper specimen with a hard En31 ball in a test rig that has facility to measure the coefficient of friction. Based on the findings of friction coefficient in these experiments, friction power has been estimated and was found to be in the typical range. Scuffing studies were undertaken both by observation of the slid surface of En31 sphere in a ferrographic microscope with camera facility as well as by calculation of the friction power.

The boundary lubricant was found to have profound role in safeguarding the surface from severe deformation and micro‐cracks. Scanning electron microscope (SEM) examination of the craters produced by LOSOPIT has given evidence that using the boundary lubricant resulted in smooth transfer of shear stress from the sphere to the specimen surface through the boundary lubricant layer. Owing to this, the asperities have been found flattened in a smooth manner instead of metal at the surface being scuffed. A limited amount of reduction was found in the coefficient of friction due to the use of boundary lubricant from that in the dry testing.

The model used to estimate the friction power is predominantly governed by the friction coefficient itself rather than either the normal load or the sliding speed. Friction coefficient itself may be contributed by various mechanisms all of which may not equally contribute to scuffing. Study is underway to carefully glean out those components of friction that exactly result in scuffing, and to use more effective criteria for scuffing.

The knowledge and data developed in the paper give a clear explanation of conditions under which scuffing can take place in sliding contacts operating under boundary regime. The most important applications are metalforming and metal cutting. It is relevant to mechanical engineering machinery in which intense contact pressures are expected.

This paper fills the gap of lack of scuffing studies in plastic deformation processing. All earlier studies focused on elastic conditions prevailing at the contact. Since, industry has been witnessing a need to tackle the severe problems related to formed product quality and certain defects hitherto unexplained, this paper gives a new direction to explain the defects in products from scuffing point of view. In this paper, it has been shown that friction power can be a good criterion to represent scuffing intensity in boundary lubrication.

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, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/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 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

Among lubrication processes for cold forging of steel, phosphating is the most common. Depending on contact between piece and phosphating solution, the success of this treatment depends on steel surface preparation. Despite this obvious fact, the influence of cleaning pretreatments such as degreasing and acid pickling are seldom considered from a mechanical point of view and specially from a tribological one. Through a tribological test, the preparation of the surface of steel billets to be zinc phosphated and soaped was studied. Having shown the importance of degreasing, this study tries to connect the parameters of warm acid pickling, such as bath composition and dipping time to the tribological performances of the coated part.

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.

This paper gives a bibliographical review of the finite element modelling and simulation of indentation testing from the theoretical as well as practical points of view. The bibliography lists references to papers, conference proceedings and theses/dissertations that were published between 1990 and 2002. At the end of this paper, 509 references are listed dealing with subjects such as, fundamental relations and modelling in indentation testing, identification of mechanical properties for specific materials, fracture mechanics problems in indentation, scaling relationship for indentation, indenter geometry and indentation testing.