Elastic-plastic finite-element modelling of a cold-extrusion process using a microcomputer-based system

Abstract

A microcomputer system is used to conduct a non-linear finite-element simulation of cold backward-extrusion. This can be used to provide reliable estimates of metal flow, generalised stress and strain distributions in the workpiece, hardness distributions, and forming force. The finite-element analysis is a small-strain formulation for elastic-plastic work-hardening materials, and includes a realistic model of interface friction. The system includes a facility for semi-automatic mesh generation which can be used for the initial mesh or for re-zoned meshes required during the simulation. The graphical display includes a super-grid representation to illustrate the deformation of the initial mesh at large plastic strains. Practical observations are compared with the finite-element predictions. The results clearly demonstrate the potential of microcomputers for non-linear analyses, and illustrate the use of microcomputers as low-cost aids to the optimisation of manufacturing processes. © 1988.