The realistic simulation of metalforming process chains

In this paper some actual developments concerning realistic simulation of metal forming processes by use of the finite element method are discussed. An algorithm, which was developed at the IBF, for visualisation of the material flow in a process chain is illustrated by means of the example of manufacturing a profiled ring. Further it is shown that for faster analysis also of massive forming processes the use of an explicit finite element formulation is sensible. Another contribution for realistic simulation is coupling the finite element method with physically‐based material models. The integration of a dislocation density model in a finite element model is illustrated by means of the example of a hot rolling process.