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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.

A new method of three‐dimensional remeshing is proposed for thermo‐viscoplastic finite element analysis of connecting rod forging. In the method, the deformed body to be remeshed is divided into a surface‐adaptive layer (SAL) and a core region. At the surface layer of hexahedral elements, the arrangement of nodal points is made by normal projection of boundary nodes in order to retard the mesh degeneracy, since the arrangement of boundary nodes can be easily achieved by using the information of the die surface patch. After generating the mesh automatically at the surface‐adaptive layer, the core region is automatically meshed by introducing a body‐fitted mapping technique. In order to show the effectiveness of the method in the three‐dimensional problem, forging of a connecting rod has been simulated as a practical example. The complete simulation of connecting rod forging has been carried out by using the thermo‐viscoplastic finite element method and the remeshing scheme. The analysis of transient heat transfer has been carried out for the workpiece by the finite element method, while the boundary element method has been used for the die.

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.

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.

The present paper addresses the computer modelling of pipe formation in metal castings.

As a preliminary, a brief review of the current state‐of‐the‐art in pipe shrinkage computation is presented. Then, in first part, the constitutive equations that have to be considered in thermomechanical computations are presented, followed by the main lines of the mechanical finite element resolution. A detailed presentation of an original arbitrary Lagrangian‐Eulerian (ALE) formulation is given, explaining the connection between the Lagrangian and the quasi Eulerian zones, and the treatment of free surfaces.

Whereas most existing methods are based on thermal considerations only, it is demonstrated in the current paper that this typical evolution of the free surface, originated by shrinkage at solidification front and compensating feeding liquid flow, can be effectively approached by a thermomechanical finite element analysis.

Future work should deal with the following points: identification of thermo‐physical and rheological data, automatic and adaptive mesh refinement, calculation of the coupled deformation of mold components, development of a two‐phase solid/liquid formulation.

An example of industrial application is given. The proposed method has been implemented in the commercial software THERCAST^® dedicated to casting simulation.

The proposed numerical methods provide a comprehensive approach, capable of modelling concurrently all the main phenomena participating in pipe formation.

An adaptive mesh refinement procedure that uses nodeless variables and quadratic interpolation functions is presented for analysing transient thermal problems. A temperature based finite element scheme with Crank‐Nicolson time marching is used to obtain the thermal solution. The strategies used for mesh adaptation, computing refinement indicators, and time marching are described. Examples in one and two dimensions are presented and comparisons are made with exact solutions. The effectiveness of this procedure for transient thermal analysis is reflected in good solution accuracy, reduction in number of elements used, and computational efficiency.

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.

The purpose of this paper is to present original methods related to the modeling of material deposit and associated heat sources for finite element simulation of gas metal arc welding (GMAW).

The filler deposition results from high-frequency impingements of melted droplets. The present modeling approach consists of a time-averaged source term in the mass equation for selected finite elements in the fusion zone. The associated expansion of the mesh is controlled by means of adaptive remeshing. The heat input includes a volume source corresponding to the droplets energy, for which a model from the literature is expressed in coherency with mass supply. Finally, an inverse technique has been developed to identify different model parameters. The objective function includes the differences between calculations and experiments in terms of temperature, but also shape of the fusion zone.

The proposed approach for the modeling of metal deposition results in a direct calculation of the formation of the weld bead, without any a priori definition of its shape. Application is shown on GMAW of steel 316LN, for which parameters of the model have been identified by the inverse method. They are in agreement with literature and simulation results are found quite close to experimental measurements.

The proposed algorithm for material deposit offers an alternative to the element activation techniques that are commonly used to simulate the deposition of filler metal. The proposed inverse method for parameter identification is original in that it encompasses an efficient and convenient technique to take into account the shape of the fusion zone.

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.

This paper proposes a new visco‐elastoplastic constitutive model for asphalt concretes able to reproduce the non linear time‐dependent behaviour of such materials.The constitutive model has been developed with the aim of making it fit specific experimental features previously observed. Moreover the proposed formulation will be demonstrated to be fully consistent with general thermodynamic requirements. Apart from a rigorous analytical formulation; a corresponding rheological sketch of the model is also given. From this representation, it can be shown that the model is essentially a combination of a generalized Maxwell model and a hardening visco‐plastic element.