Until now considerable simplifications have been necessary in order to make FEM computations of the cross-roll piercing process. Using a new innovative approach it is now possible to completely simulate this process in three dimensions. For the first time it is possible to perform FEM simulations capable of describing the geometry and kinematics of the rotary piercing process without excessive simplifications. The algorithms applied for regenerating and modifying the FE mesh are stable. A comparison of fundamental investigations of the past century reveals an essentially good correlation between modern numeric simulation and older model studies.
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