Aspects of modelling and computation in the analysis of metal forming

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.