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Under restriction of an isotropic elastic response of deformed lattice, develops a covariant theory of finite elastoplasticity in principal axes of a pair of deformation tensors. In material description, the tensor pair consists of the plastic deformation tensor and the total deformation Cauchy‐Green tensor. Applies the proposed theory to elastoplastic membrane shells, whose references and current configurations can be arbitrary space‐curved surfaces. Pressure‐insensitive von Mises yield criterion with isotropic hardening and a quadratic form of the strain energy function given in terms of elastic principal stretches are considered as a model problem. Through an explicit enforcement of the plane stress condition we arrive at a reduced two‐dimensional problem representation, which is set in the membrane tangent plane. Numerical implementation of the presented theory relies crucially on the operator split methodology to simplify the state update computation. Presents a set of numerical examples in order to illustrate the performance of the presented methodology and indicate possible applications in the area of sheet metal forming.

In order to develop an engineering tool for modelling 2D metal forming processes we implemented in the flow formulation the pseudo‐concentrations technique and a quadrilateral element based on mixed interpolation of tensorial components (QMITC). By doing this we obtained a reliable and efficient Eulerian formulation for modelling steady and transient metal forming problems. Some cases were analysed in order to test the performance of the formulation.

Numerical modelling and simulation of metal forming is rapidly gaining prominence in many industries all over the world due to its effective saving of production time, effort and economy. In order to meet this need a special finite element code FORGE2 has been developed at CEMEF. In this work the theoretical basis of the FORGE2 along with its features such as thermo‐viscoplastic coupling, material compressibility and automatic mesh regeneration is reviewed and an attempt is made to simulate a few industrial forming processes taking into account the complex friction phenomena and thermal environment.

A finite element model for numerical simulation of non‐steady but continuous chip formation under orthogonal cutting conditions is described. The problem is treated as coupled thermo‐mechanical. A velocity approach has been adopted for the proposed solution. The computational algorithm takes care of dynamic contact conditions and makes use of an automatic remeshing procedure. The results of simulation yield complete history of chip initiation and growth as well as distributions of strain rate, strain, stress and temperature. The paper includes a detailed presentation of computational results for an illustrative case.

A synopsis is presented of the numerical finite element methodology currently in use at the Institute for Computer Applications (ICA) for the simulation of industrial forming processes. The development of the method is based on the inelastic properties of the material with an extension towards the inclusion of elastic effects and accounts for the thermal phenomena occurring in the course of the deformation. An essential constituent of the computational procedure is the treatment of the unsteady contact developing between the workpiece material and the tool during forming, and of the associated friction phenomena. Automatic mesh generation and variable discretization adaptable to the development of the numerical solution are of importance for industrial applications. These aspects are presented and discussed. Furthermore, solution techniques for thermomechanically coupled problems are considered and investigated with respect to their numerical properties. Application to industrial forming processes is demonstrated by means of three‐dimensional hot rolling and of superplastic sheet forming.

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.

A numerical model for solving either elastic‐plastic, elastic‐viscoplastic or purely viscoplastic deformation of thin sheets is presented, using a membrane mechanical approach. The finite element method is used associated with an incremental procedure. The mechanical equations are the principle of virtual work written in terms of plane stress, which is solved at the end of each increment, and an incremental semi‐implicit flow rule obtained by the time integration of the constitutive equations over the increment. These equations are written using curvilinear coordinates, and membrane elements are used to discretize them. The resolution method is the Newton‐Raphson algorithm. The contact algorithm is presented and allows for applications to cold stretching and deep‐drawing problems and to the superplastic forming of thin sheets.

The non‐isothermal filling of a powder/binder mixture in metal injection moulding is simulated by the viscoplastic and the heat conduction finite element methods. Proposes a simplified three‐dimensional scheme for the moulding of products with a non‐uniform thickness distribution. The computing time for the simplified three‐dimensional scheme is of the same order as that for two‐dimensional problems. Deals with complex overlapping between the surfaces of the mixture, resulting from the occurrence of jetting during the moulding, by the use of a remeshing scheme. The material flow in metal injection moulding into a rectangular die with a linear thickness distribution is simulated. The jetting behaviour is remarkably influenced by the thickness distribution of the die.

This article focuses on the comparative study of annular wire‐coating flows with polymer melt materials. Different process designs are considered of pressure‐ and tube‐tooling, complementing earlier studies on individual designs. A novel mass‐balance free‐surface location technique is proposed. The polymeric materials are represented via shear‐thinning, differential viscoelastic constitutive models, taken of exponential Phan‐Thien/Tanner form. Simulations are conducted for these industrial problems through distributed parallel computation, using a semi‐implicit time‐stepping Taylor‐Galerkin/pressure‐correction algorithm. On typical field results and by comparing short‐against full‐die pressure‐tooling solutions, shear‐rates are observed to increase ten fold, while strain rates increase one hundred times. Tube‐tooling shear and extension‐rates are one quarter of those for pressure‐tooling. These findings across design options, have considerable bearing on the appropriateness of choice for the respective process involved. Parallel finite element results are generated on a homogeneous network of Intel‐chip workstations, running PVM (Parallel Vitual Machine) protocol over a Solaris operating system. Parallel timings yield practically ideal linear speed‐up over the set number of processors.

A finite‐element model for calculating the die temperature profile for a hot‐forging operation is presented. The workpiece is modelled as a thermo‐viscoplastic material, while the dies are considered undeformable. Heat transfer between the dies and the workpiece is modelled using an iteratively coupled, fixed‐point calculation of the temperature in each domain. Transfer of temperature boundary conditions across contact interfaces is performed for non‐coincident meshes, using a boundary integration point contact analysis. Two industrial‐type examples are presented. In the first example, the effectiveness of the transfer of the temperature boundary conditions for a non steady‐state forging process is evaluated and determined to be satisfactory. Then weakly‐ and strongly‐coupled temperature resolutions are compared. It was found that the strongly‐coupled resolution may be necessary in order to obtain reasonably accurate results. In the second example, the weakly‐coupled resolution is compared to a constant‐temperature die approach for a relatively slow forging process, which shows the influence of the die temperature on the flow of the material.