Applications of Finite Element Modeling in Industrial Forming Processes at the Timken Company

Abstract

Advances in stabilized finite element methods for bulk and sheet metal forming processes AIP Conf.Abstract. At The Timken Company, finite element modeling has been utilized successfully to design, improve and optimize metal forming processes in many areas from steel making processes for long products and tubes, and forming and shaping of discrete parts. It is very challenging to apply the finite element modeling to most incremental forming processes due to continuously changing contact conditions between workpiece and forming tools. This paper illustrates the use of different finite element formulations for the analysis of various incremental forming processes. Each finite element analysis (FEA) program has its own advantages and disadvantages in the areas of computational time and accuracy of results, so the selection of proper program to analyze a certain process is quite significant. Unique applications of FEA programs to assist the design of tooling and process parameters of several forming processes at The Timken Company are discussed. The analysis results of several cases were compared with available in-plant data and excellent agreement was observed.

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