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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 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 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 modern aeroplane is constructed largely from sheet metal. As such, the most important production problems are those of sheet metal forming, and assembling. Production is here considered as not only the act of forming and assembling the required number of parts, but also the making of forming tools, and all processing of parts such as heat‐treating. Only that phase of the above concept of production which deals with the tooling for production and the forming and heat‐treating will be considered here. The design of the aircraft parts will also be discussed somewhat, for it is obvious that the design of the part (designed shape and materials used) frequently determines whether the part can or cannot be readily made.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

Material-based computation has been recently introduced in architectural education, where parameters and rules related to materials are integrated into algorithmic thinking. The authors aim to identify affordances of material-based computation in terms of supporting the understanding of parametric design, informing the process of parametric form finding in an educational setup and augmenting student learning outcomes.

The authors propose a material-informed holistic systems design framework for parametric form finding. The authors develop a pedagogical approach that employs material-based computation focusing on the interplay between the physical and the digital in a parametrically driven façade design exercise. The approach comprises two phases: (1) enabling physical exploration with different materials to arrive at the design logic of a panel prototype and (2) deducing embedded and controlled parameters, based on the interplay of materials and deriving strategies for pattern propagation of the panel on a façade composition using variation and complexity.

The results confirmed the initial hypothesis, where the more explicit the material exploration and identification of physical rules and relations, the more nuanced the parametrically driven process, where students expressed a clear goal oriented generative logic and utilized parametric design to inform form finding as a bottom-up approach.

Most precedent approaches developed to teach parametric design concepts in architectural education have focused on universal strategies that often result in fixating students on following standard blindly followed scripts and procedures, thus defying the purpose of a bottom-up form finding framework. The approach expands the pedagogical strategies employed to address parametric design as a form finding process.

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 introduces a new subject called bio‐manufacturing. Bio‐manufacturing combines life science with manufacturing science, and uses manufacturing method to form materials with bio‐activity and bio‐degradability into scaffolds. In this paper, we discuss the hierarchy of bio‐manufacturing: the lower grade uses undegradable bio‐material to form permanent organ replacement such as auricular cartilage and the higher grade uses biodegradable bio‐materials to repair organ damage or organ replacement which degrades after embedded in the human body. They all adopt jetting/extrusion deposition process (fused deposition modelling or 3D printer), the distinct different point being the temperature of the forming chamber. The samples of bones and auricular cartilage produced by those processes had been practiced on dogs and rabbits, repaired their damage.

The purpose of this paper is to provide industrial, education and academic users of computer programs a basic overview of finite elements in metal forming that will enable them to recognize the pitfalls of the existing formulations, identify the possible sources of errors and understand the routes for validating their numerical results.

The methodology draws from the fundamentals of the finite elements, plasticity and material science to aspects of computer implementation, modelling, accuracy, reliability and validation. The approach is illustrated and enriched with selected examples obtained from research and industrial metal forming applications.

The presentation is a step towards diminishing the gap being formed between developers of the finite element computer programs and the users having the know‐how on the metal forming technology. It is shown that there are easy and efficient ways of refreshing and upgrading the knowledge and skills of the users without resorting to complicated theoretical and numerical topics that go beyond their knowledge and most often are lectured out of metal forming context.

The overall content of the paper is enhancement of previous work in the field of sheet and bulk metal forming, and from experience in lecturing these topics to students in graduate and post‐graduate courses and to specialists of metal forming from industry.

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.

Custom-designed metal bellows require alternate ways to produce the die to shorten lead time. The purpose of this study is to explore the possibility of using Additive Manufactured (AM) polymer die as direct rapid tool (RT) for metal bellow hydroforming.

Finite element analysis (FEA) was used to simulate bellow forming and to evaluate the compatibility of AM die. Fused deposition modelling (FDM) technique is used to fabricate die with Acrylonitrile Butadiene Styrene (ABS) material. To validate, the width of the metal bellow convolutions obtained from the FEA simulation is compared with convolution formed during the experiment.

FDM-made die can be used for a short production run of bellow hydroforming. FEA simulation shows that stress developed in some regions of die is less and these regions have potential for material reduction. Use of RT for this particular application is limited by the die material, forming pressure, width, convolution span and material of bellow. This supports the importance of FEA validation of RT before fabrication to evaluate and redesign die for the successful outcome of the tool.

The given methodology may be followed to design a RT with minimum material consumption for bellow forming application. Whenever there is a change in bellow design or the die material, simulation has to be done to evaluate the capability of the die. As this study was focused on a short production run for manufacturing one or few bellows, the die life is not a significant factor.

This paper demonstrates about rapid tooling for metal bellow manufacturing using FDM technique for low volume production. Further, FEA is used to identify low stress regions and redesign the die for material reduction before die manufacturing. AM die can be used for developing customized metal bellow for applications such as defense, aerospace, automobiles, etc.