Multi‐level simulation of metal‐forming processes

The IBF has for some years made use of finite element programmes to solve metal‐forming problems. In the course of this investigation, it has become evident that a problem‐oriented adaptation of FEM simulation to the problem in hand is beneficial in terms of computation effort. The computation time for the process parameters is optimised in a multi‐level simulation. At level 1 (global analysis) integral parameters such as the required force and required work are computed using a coarse FEM mesh. At level 2 (local analysis) an optimised number of elements is used to determine continuum mechanics parameters like stress, strain and temperature. Microscopic phenomena are simulated at level 3 (microscopic analysis), using special micro‐material elements and thermodynamic models.