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International audienceWithin the frame of implicit velocity based formulations with solid elements, usual time integration schemes often turn out unsatisfactory when the movement has large rotations, especially in metal forming applications such as ring rolling or cross-wedge rolling. These rotations generally require using a much higher order integration scheme with inherent difficulties in implementing such schemes. For pure rotation motions, it is possible to use a low order integration scheme by rewriting the motion equations in the cylindrical frame that is supported by the rotation axis. Accordingly, a first order scheme is sufficient to accurately integrate the movement but it is restricted to specific problems. In the more general case, it is possible to derive parts of the domain where rotations are predominant along with the governing rotation axis from the velocity field gradient. The motion equations are then rewritten in the resulting local cylindrical frame. Performances of this first order scheme are first evaluated and highlighted over simple analytical problems, before being applied to the finite element simulation of the torsion test, and then to more complex metal forming problems involving large rotations. The accuracy and efficiency of this scheme is so numerically demonstrated

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In the field of materials forming processes, the use of simulation coupled with optimization is a powerful numerical tool to support design in industry and research. The finite element software Forge®, a reference in the field of the two-dimensional and three-dimensional simulation of forging processes, has been coupled to an automatic optimization engine. The optimization method is based on meta-model assisted evolutionary algorithm. It allows solving complex optimization problems quickly. This paper is dedicated to a specific application of optimization, inverse analysis. In a first stage, a range of reverse analysis applications are considered such as material rheological and tribological characterization, identification of heat transfer coefficients and, finally, the estimation of Time Temperature Transformation curves based on existing Continuous Cooling Transformation diagrams for steel quenching simulation. In a second part, a novel inverse analysis application is presented in the field of cold sheet forming, the identification of the material anisotropic constitutive parameters that allow matching with the final shape of the component after stamping. The advanced numerical methods used in this kind of complex simulations are described along with the obtained optimization results. This article shows that automatic optimization coupled with Forge® can solve many inverse analysis problems and is a valuable tool for supporting development and design of metals forming processes.

The present work concerns the simulation of metallurgical evolutions in 3D multi-pass forming processes. In this context, the analyzed problem is twofold. One point refers to the management of the microstructure evolution during each pass or each inter-pass period and the other point concerns the management of the multi-pass aspects (different grain categories, data structure). In this framework, a model is developed and deals with both aspects. The model considers the microstructure as a composite made of a given (discretized) number of phases which have their own specific properties. The grain size distribution and the recrystallized volume fraction distribution of the different phases evolve continuously during a pass or inter-pass period. With this approach it is possible to deal with the heterogeneity of the microstructure and its evolution in multi-pass conditions. Both dynamic and static recrystallization phenomena are taken into account, with typical Avrami-type equations. The present model is implemented in the Finite Element code FORGE2005®. 3D numerical simulation results for a multi-pass process are presented.