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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.

Addresses the computational aspects involved in the numerical simulation of sheet stamping processes. Focuses on some numerical aspects of the intrinsic complexity of these problems, the first of which is the necessity to take into account properly membrane and bending effects. Presents a well‐adapted shell element. The second aspect concerns the description and the implementation of the initial orthotropic plastic behaviour for sheet metal parts, based on a formulation in a rotating frame using the initial microstructure rotation. The stress calculation algorithm is based on a particular implementation of the elastic predictor‐plastic corrector method. The last aspect concerns the solution procedures with a particular development concerning the treatment of the blankholder load as a constraint. A set of computational results validated with experiments prove the accuracy of the proposed approach in solving stamping problems.

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.

In this paper, we are interested in the forming of composite part by deep‐drawing and laying‐up processes. We present a new finite element model for the simulation of these processes. The augmented Lagrangian approach is adopted to treat the frictional contact between the composite fabric and the tools. It is based on a new way of writing the Coulomb’s friction law. The numerical simulation is carried out with Abaqus/Explicit software and some numerical results are given to validate the proposed numerical method.

This paper gives a bibliographical review of the finite element methods (FEMs) applied to the analysis of ceramics and glass materials. The bibliography at the end of the paper contains references to papers, conference proceedings and theses/dissertations on the subject that were published between 1977‐1998. The following topics are included: ceramics – material and mechanical properties in general, ceramic coatings and joining problems, ceramic composites, ferrites, piezoceramics, ceramic tools and machining, material processing simulations, fracture mechanics and damage, applications of ceramic/composites in engineering; glass – material and mechanical properties in general, glass fiber composites, material processing simulations, fracture mechanics and damage, and applications of glasses in engineering.

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.

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.

This paper gives a bibliographical review of the finite element and boundary element parallel processing techniques from the theoretical and application points of view. Topics include: theory – domain decomposition/partitioning, load balancing, parallel solvers/algorithms, parallel mesh generation, adaptive methods, and visualization/graphics; applications – structural mechanics problems, dynamic problems, material/geometrical non‐linear problems, contact problems, fracture mechanics, field problems, coupled problems, sensitivity and optimization, and other problems; hardware and software environments – hardware environments, programming techniques, and software development and presentations. The bibliography at the end of this paper contains 850 references to papers, conference proceedings and theses/dissertations dealing with presented subjects that were published between 1996 and 2002.

The effect of bending is investigated through the comparison of the membrane analysis and the shell analysis for stretching and deep drawing. An incremental formulation incorporating the effect of shape change and anisotropy is used for the analysis of elastic‐plastic non‐steady large deformation. The deformation during a step is considered using the natural convected coordinate system. Stretching of a square blank with a hemispherical punch and deep drawing of a cyclindrical cup is analysed and the corresponding experiments are carried out. The computational results are compared with the experiments. In stretching, the comparison has shown that both the membrane analysis and the shell analysis are in good agreement with the experiment for punch load and strain distribution. In deep drawing, the computed loads of both the membrane analysis and the shell analysis are generally in good agreement with the experiment. The computed thickness strain of the membrane analysis, however, shows a wide difference with the experiment. In the shell analysis, the thickness strain shows good agreement with the experiment. It has been shown that the membrane approach shows a limitation for the deep drawing process in which the effect of bending is not negligible and more exact informations on the thickness strain distribution are required.

The constitutive equations for the deformation of elastoplastic, viscoplastic or compressible materials are presented for the small strain approximation and for the large strain theory of Hill. A velocity approach is proposed for time discretization, which leads to a second order approximation for small strain, and an incrementally objective second order approximation for large deformation processes. Two other quasi second order formulations are discussed. The finite element space discretization is outlined and the solution procedure is described.