Non-Isothermal FEM Analyses of Large-Strain Back Extrusion Forging

摘要

Back extrusion forging is a complex metal forming operation dominated by large-strain, non-isothermal deformation. NIKE2D, a fully vectorized implicit finite-element program developed at Lawrence Livermore National Laboratory, was applied to a two-stage isothermal back extrusion forging process. Modeling of the forging process required special features in the FEM code such as friction and interactive rezoning that allows for remeshing of the distorted mesh while maintaining a complete history of all the state variables. To model conditions of the non-isothermal forging process required implementing TOPAZ2D, our LLNL-developed two-dimensional implicit finite element code for heat conduction analysis, as a subroutine into NIKE2D. The fully coupled version maintains all the original features of both codes and can account for the contribution of heat generation during plastic deformation. NIKE/TOPAZ-2D was applied to the piercing operation of the back extrusion forging process. The thermal deformation history of the die, punch, and workpiece and the effective plastic strains were calculated. (ERA citation 11:051293)