Cold forging is the most efficient technology for high volume production of near-net-shape and ready to assemble components for transport, mechanical , electrical and other industries.  In this highly competitive industry the success depends on ability to efficiently compute deflections that simultaneously interact in a combined workpiece-die-press system and  to optimize precision of parts and service life of tooling systems by taking into account all relevant process parameters. Smooth contact elements and large strain plasticity elements were used to make simulation of the two-phase forging process in the example. Implementation of the complex scenario involved is a difficult task for most of the commercial finite element systems. The flexibility of data manipulations in Mathematica and the structure of AceFEM where all the data can be access and changed directly from Mathematica is proved to be an efficient combination for the implementation of complex scenarios.


The example kindly provided by Institute of Fundamental Technological Research,Warszawa,Poland and Centre for Computational Continuum Mechanics, Ljubljana, Slovenia.