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Enhanced Framework for Forging Design Using Reliable Three-Dimensional Simulation


The objective in the present project is to develop the Finite Element Method to 3D problems for the application as a process and product development and quality assurance system related to metal forming production. The challenge is the implementation of a realistic constitutive law describing the material behaviour and the
toolworkpiece interface conditions as regards friction and heat transfer as well as an accurate description of a finite element mesh evolution under large strain conditions. Several teams in Europe are in phase of developing 3D finite element models but they have so far not succeeded to market them due to a lack of reliable automatic remeshing facilities. However for an accurate and economical treatment of forming problems in industry not only a remeshing technique is required. It is also to be adapted and based on an a posteriori error estimation in order to refine the mesh where strain and temperature localisation occurs.

The project is of interest to forging industry, material and press manufacturers and to end users such as car manufacturers, aeronautical industry and other mechanical industry. The partnership structure is the following:

Four research laboratories, CEMEF ( France ) material forming center, laboratory of Ecole des Mines de Paris with experience in finite element modelling of material forming processes and development of industrial codes for forging processes simulation, DIMEG from the University of Padova ( Italy ) in studying the materials behaviour in warm and hot forging and physical simulation of ther nal and mechanical events and the interface conditions as regards heat transfer, DTU, the Technical University of Denmark ( Denmark ) with expertise in physical modelling using soft model materials as well as metals, and analysis of tools workpiece interface conditions in terms of friction and heat transfer, KTH, Royal Institute of Technology ( Sweden ) in analysis of materials behaviour in cold forging * Four forging companies SIFCOR ( France ), TEKSID ( Italy ) RATEC ( Norway ) and Tour and Andersson Hydronics ( Norway )
Two software companies TRANSVALOR ( France ) marketing of the FORGE3 code, in close contact with forging industry and DELCAM ( United Kingdom ) marketing of the DUCT software for CAD/CAM

The study will focus on cold, warm, and hot forging / extrusion of steel, and alloys of aluminium, copper, brass as well as advanced structural light metals. The proposed approach will allow to analyse the following:
Process: flow, form filling, strains, strain rates, stresses, temperature
Workpiece: material, microstructure, ductility, strength, residual stresses, geometry, tolerances, defects.
Tool: stresses, temperature

The expertise of the individual partners makes it possible to propose a complete package of development and validation activities on a 3D forging code including physical, numerical, experimental components as well as thorough industrial validation. The work programme below shows the main technical tasks:
Numerical development of a 3D forging code: adaptive
remeshing, contact treatment
Material properties in cold and warm/hot forming
Conditions at toolworkpiece interface in friction and heat transfer evaluation
Physical modelling validation
Numerical modelling validation
Industrial validation on complex pieces

Call for proposal

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Participants (9)