RECENT DEVELOPMENT OF PROCESS SIMULATION AND ITS APPLICATIONS TO MANUFACTURING PROCESSES

In this paper, the methodology of an Finite Element Method (FEM) based process modeling program is first described using DEFORMTM as an example. DEFORMTM was originally designed for metal forming applications. While its FEM engine employs the updated Lagrangian method, DEFORMTM includes an automated remeshing procedure so as to continue the simulation when the mesh is severely distorted. Due to its unique remeshing capability, the use of the code has been extended to other manufacturing processes, such as welding, machining, heat treatment and glass forming. The heat treatment enhancement includes the phase transformation kinetics. To demonstrate the methodology, applications of the program to various manufacturing processes such as ingot breakdown, extrusion, forging and heat treatment, are presented in this paper.