Simulation of axi-symmetrical cold forging process by efficient pseudo inverse approach and direct algorithm of plasticity

This paper presents a new simplified method called “Pseudo Inverse Approach” (PIA) for the axi-symmetrical cold forging modeling. The PIA keeps the advantages of the Inverse Approach (very fast) but gives good stress estimation by taking into account the loading history. Some intermediate configurations are created by using a free surface method to consider the deformation paths without contact treatment. A new direct algorithm of plasticity is developed leading to a fast and robust plastic integration procedure for very large strain increments. The PIA results are compared to those obtained by using ABAQUS software to show the efficiency and limitations of the PIA.

► We propose a new approach called “Pseudo Inverse Approach” for forging simulation. ► We introduce some intermediate configurations to consider the deformation path. ► Intermediate configurations are created using a free surface method. ► To avoid contact treatment, the tool actions are represented by nodal forces. ► A new fast and robust direct algorithm of plasticity is developed.