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Reprinted with permission from AIP Conf. Proc.May 17, 2007 -- Volume 908, pp. 257-262 MATERIALS PROCESSING AND DESIGN; Modeling, Simulation and Applications; NUMIFORM '07; Proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes; doi:10.1063/1.2740821 Copyright 2007 American Institute of Physics. This article may be downloaded for personal use only. Any other use requires prior permission of the author and the American Institute of PhysicsInternational audienceThe process of flow forming is numerically modeled using finite element codes based on the Forge2005® software. Two numerical approaches are considered. The first one uses an updated Lagrangian formulation. The problem is solved with help of a self-contact management algorithm. The second approach consists in using an ALE formulation that permits to optimize meshing with an adaptive method based on the Zienkiewicz-Zhu error estimation. The ALE method is well adapted to incremental forming processes such as flow forming and allows dealing with difficulties generated by the contact between the work piece and tools. Both formulations are coupled with complex tool kinematics. The Lagrangian formulation gives realistic results. The ALE formulation is promising with regard to computational time, and simulations on simple configurations show fairly good agreements with Lagrangian results

3D FEM Simulation of the Flow Forming Process Using Lagrangian and ALE Methods