A BEM/FEM Framework for Simulation of a Plastic Workpiece Deformed by an Elastic Tool

Abstract

A solution methodology is developed for the simulation of a plastic workpiece deformed by a compliant tool. The solution for elastic tool displacements is based on the Boundary Element Method (BEM); the viscoplastic response of the workpiece is computed using the Finite Element Method (FEM). At each time increment, tool deflections are recomputed from the elastic solution based on surface tractions developed in the previous converged solution for the viscoplastic response of the workpiece material. Tool stresses may be recovered at any point in the simulation using the BEM solution. The updated tool geometry and motion correspondingly modify the kinematic contact constraint applied in the viscoplastic solution over the subsequent time step. Application of this methodology is demonstrated for simulation of a plane strain forging operation.