Forge3 (R) - a general tool for practical optimization of forging sequence of complex three-dimensional parts in industry

Numerical simulation of forming processes by the computer code Forge3(R) requires the description of a precise thermal and mechanical framework. The integral formulation of the problem is recalled and applied to the finite element with a mixed velocity and pressure formulation. The time discretisation scheme is presented with the incremental unilateral contact problem. During forging simulation of a complex part, the elements undergo excessive distortion so that a new mesh must be periodically rebuilt. 3-D automatic meshing and remeshing method are based on the concept of topology, which is particularly suited for local rezoning. Alternatively the ALE (Arbitrary Lagrangian Eulerian) method is introduced as a way to decrease the number of remeshing, The parallel version of Forge3(R) was developed, with an iterative method for solving linear system, and applied to the computation of complex parts discretised with a very large number of nodes.