Faculty of Engineering – Alexandria University
Department of Production
Finite Element Analysis of Metal Forming
Modeling Forming Processes
Prepared for: Dr. Mohamed Abd-Alrazzaq
Prepared by: Jasser Ashraf Mahmoud
ID: 21010406
August 2025
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Contents
ABSTRACT ......................................................................................................... 3
INTRODUCTION............................................................................................... 4
Fundamentals of Finite Element Analysis ........................................................ 4
• Meshing ...................................................................................................... 4
Definition and Purpose ................................................................................. 4
Process Overview.......................................................................................... 5
Importance of Meshing in FEA .................................................................... 5
• Stress–Strain Relationships ..................................................................... 6
• Boundary Conditions ............................................................................... 9
Applications of FEA in Metal Forming............................................................. 9
• General Applications ................................................................................ 9
• Deep Drawing Simulation ...................................................................... 10
• Rolling Process Analysis ......................................................................... 10
• Forging Simulations ............................................................................... 10
FEA in metal forming faces several key challenges and limitations: ........... 10
Conclusion.......................................................................................................... 11
References .......................................................................................................... 12
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ABSTRACT
In the late 1970s and early 1980s, the use of computer-aided techniques (computer-
aided engineering, design, and manufacturing) in the metal-forming industry increased
considerably. The trend seems to be toward ever-wider application of this technology
for process simulation and process design. A key goal in manufacturing research and
development is to determine the optimal means of producing high-quality products.
The optimization criteria may vary, depending on product requirements, but
establishing an appropriate criterion requires a thorough understanding of
manufacturing processes. In metal-forming technology, proper design and control
needs, among other things, the determination of deformation mechanics involved in
the processes. Without the knowledge of the influences of variables such as friction
conditions, material properties, and workpiece geometry on the process mechanics, it
would not be possible to design the dies and the equipment adequately, or to predict
and prevent the occurrence of defects. indicates the role of process modeling in some
detail. In the past, several approximate methods of analysis have been developed and
applied to various forming processes. The methods most well known are the slab
method, the slip-line field method, the visioplasticity method, upper- (and lower-)
bound techniques, Hill’s general method, and, more recently, the finite-element
method (FEM). In the slab method, the workpiece being deformed is decomposed into
several slabs. For each slab, simplifying assumptions are made mainly concerning
stress distributions. The resulting approximate equilibrium equations are solved with
the imposition of stress compatibility between slabs and boundary tractions. The result
is a reasonable load prediction with an approximate stress distribution. The slip-line
field method is used in plane strain for perfectly plastic materials (constant yield
stress) and uses the hyperbolic properties that the stress equations have in such cases.
The construction of slip-line fields, although producing an “exact” stress distribution,
is still quite limited in predicting results that give good correlations with experimental
work. From the stress distributions, velocity fields can be calculated through plasticity
equations.
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INTRODUCTION
Finite Element Analysis of Metal Forming uses numerical simulation to
understand and predict the behaviours of the metal during forming processes, to
achieve the best design, quality, and lowest cost.
Material Forming is Materials are converted into finished products through
different manufacturing processes. Manufacturing processes are classified into
shaping [casting], forming, joining, coating, dividing, machining, and
modifying material properties.
We use FEA in metal forming to solve complex problems in machines
Fundamentals of Finite Element Analysis
• Meshing
Definition and Purpose
Meshing in Finite Element Analysis (FEA) is the process of breaking down a
complex, continuous geometric space into smaller, manageable elements, or
'meshes'. This discretization allows for the numerical approximation of physical
phenomena, translating intricate structures into a finite set of equations solvable
by computers. The mesh serves as the backbone for the entire FEA process,
providing a framework upon which calculations regarding stress, strain, heat
transfer, and other physical attributes are conducted. It's the bridge between a
theoretical model and a practical simulation, converting abstract concepts into
tangible data.
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• Process Overview
The mesh generation process starts with defining the geometry of the object or
space under consideration. This geometry is then partitioned into elements, with
each element representing a discrete portion of the whole. The process involves
decisions on the type, size, and density of the elements, significantly influenced
by the nature of the physical problem being solved. Following mesh creation,
boundary conditions and material properties are applied, enabling the simulation
to mimic real-world scenarios accurately. The complexity of the mesh often
directly correlates with the simulation's accuracy, highlighting the critical nature
of this step in FEA.
Importance of Meshing in FEA
Meshing is a critical step in FEA as it directly impacts the accuracy and
reliability of the simulation results. A well-constructed mesh can accurately
capture the nuances of the physical model, leading to precise simulations.
Conversely, a poorly designed mesh might result in significant errors,
misleading results, or even computational failure. The mesh dictates how well
the simulation will replicate the real-world conditions, making it an
indispensable part of the FEA process.
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• Stress–Strain Relationships
Here the concepts of stress analysis will be stated in a finite element context. T
hat means that the primary unknown will be the (generalized) displacements.
All other items of interest will mainly depend on the gradient of the displaceme
nts and therefore will be less accurate than the displacements. Stress analysis c
overs several common special cases to be mentioned later. Here only two formu
lations will be considered initially. They are the solid continuum form and the
shell form. Both are offered in SW Simulation. They differ in that the continu
um form utilizes only displacement vectors, while the shell form utilizes displac
ement vectors and infinitesimal rotation vectors at the element nodes. As illustr
ated in Figure 3‐
1, the solid elements have three translational degrees of freedom (DOF) as noda
l unknowns, for a total of 12 or 30 DOF. The shell elements have three translati
onal degrees of freedom as well as three rotational degrees of freedom, for a tot
al of 18 or 36 DOF. The difference in DOF types means that moments or coupl
es can only be applied directly to shell models. Solid elements require that coup
les be indirectly applied by specifying a pair of equivalent pressure distribution
s, or an equivalent pair of equal and opposite forces at two nodes on the body.
Stress transfer takes place within, and on, the boundaries of a solid body. The di
splacement vector, u, at any point in the continuum body has the units of meters
[m], and its components are the primary unknowns. The components of displ
acement are usually called u, v, and w in the x, y, and z‐
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directions, respectively. Therefore, they imply the existence of each other, u ↔
(u, v, w). All the displacement components vary over space. As in the heat tra
nsfer case (covered later), the gradients of those components are needed but onl
y as an intermediate quantity. The displacement gradients have the units of [m/
m], or are considered dimensionless. Unlike the heat transfer case where the g
radient is used directly, in stress analysis the multiple components of the displa
cement gradients are combined into alternate forms called strains. The strains h
ave geometrical interpretations that are summarized in Figure 3‐
2 for 1D and 2D geometry. In 1D, the normal strain is just the ratio of the chan
ge in length over the original length, εx = ∂u / ∂x. In 2D and 3D, both normal s
trains and shear strains exist. The normal strains involve only the part of the gra
dient terms parallel to the displacement component. In 2D they are εx = ∂u / ∂x
and εy = ∂v / ∂y. As seen in Figure 3‐
2 (b), they would cause a change in volume, but not a change in shape of the re
ctangular differential element. A shear strain causes a change in shape. The tot
al angle change (from 90 degrees) is used as the engineering definition of the s
hear strain. The shear strains involve a combination of the components of the gr
adient that are perpendicular to the displacement component. In 2D, the engine
ering shear strain is γ = (∂u / ∂y + ∂v / ∂x), as seen in Figure 3‐
2(c). Strain has one component in 1D, three components in 2D, and six compon
ents in 3D. The 2D strains are commonly written as a column vector in finite el
ement analysis, ε = (εx εy γ)T.
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Stress is a measure of the force per unit area acting on a plane passing through t
he point of interest in a body. The above geometrical data (the strains) will be
multiplied by material properties to define a new physical quantity, the stress, w
hich is directly proportional to the strains. This is known as Hooke’s Law: σ =
E ε, (see Figure 3‐
3 ) where the square material matrix, E, contains the elastic modulus, and Poisso
n’s ratio of the material. The 2D stresses are written as a corresponding column
vector, σ = (σx σy τ)T. Unless stated otherwise, the applications illustrated
here are assume to be in the linear range of a material property. The 2D and 3D
stress components are shown in Figure 3‐
4. The normal and shear stresses represent the normal force per unit area and t
he tangential forces per unit area, respectively. They have the units of [N/m^2],
or [Pa], but are usually given in [MPa]. The generalizations of the engineering
strain definitions are seen in Figure 3‐
5. The strain energy (or potential energy) stored in the differential material ele
ment is half the scalar product of the stresses and the strains. Error estimates fr
om stress studies are based on primarily on the strain energy (or strain energy d
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ensity).
• Boundary Conditions
Practically speaking, a boundary condition is the setting of a physical
state on a portion of a model. The boundary could be a point, an edge,
or a surface. The boundary condition is a known value of a
displacement or loading. To properly understand boundary conditions,
it is necessary to relate them to reality.
Experienced engineers to also have difficulty properly defining them.
Boundary conditions have a major impact on the results of an analysis.
A small mistake when defining them can make the difference between
a correct and incorrect simulation. You will need to follow a strategy,
which will permit you to test and validate them.
Applications of FEA in Metal Forming
• General Applications
FEA applications in steel processing cover a broad spectrum of manufacturing
techniques. Engineers and designers employ FEA for:
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• Metal Forming Analysis: Simulating processes such as forging,
pressing, and rolling, which involve considerable plastic deformation.
• Stress Analysis: Assessing the response of steel components to different
loading conditions, ensuring longevity and reliability.
• Thermal Analysis: Evaluating heat treatments, cooling rates, and their
impact on mechanical properties.
• Joining Techniques: Optimizing welding, soldering, and similar methods
by determining optimal parameters and potential flaws.
Each of these applications allows for better predictive capabilities, ultimately
leading to improved functionality of the final products.
• Deep Drawing Simulation
• Rolling Process Analysis
• Forging Simulations
FEA in metal forming faces several key challenges
and limitations:
1. Time-pressure shortcuts & hardware constraints:
Techniques are often simplified to save computation time, which reduces
accuracy. Additionally, complex models require substantial computational
resources, limiting model fidelity.
2. Approximate nature and human dependency:
FEA cannot fully replicate real-world behavior; its outputs are only
approximations, and highly dependent on the skill of the operator,
software reliability, and quality of input data.
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3. Cost, complexity, convergence, storage, and communication issues:
The method is constrained by high cost, model complexity, potential
convergence difficulties, heavy storage requirements, and communication
challenges.
4. Mesh distortion in large-deformation scenarios:
When simulating processes involving significant strains, mesh distortion
can become severe, affecting simulation stability and accuracy.
Conclusion
Based on the applications and challenges of Finite Element Analysis
(FEA) in metal forming, especially in processes such as deep drawing,
forging, and rolling, it is evident that FEA has become an indispensable
tool in modern manufacturing. It enables engineers to:
• Predict formability issues—like wrinkling, thinning, and tearing—well
before production, which helps in defining optimal parameters such as
blank-holder force, friction conditions, and tool design.
• Reduce reliance on costly and time-consuming physical trials by allowing
virtual trials and iterative refinement of design choices.
• Obtain detailed insights into load requirements, strain rates, and stress
distributions, facilitating process optimization and defect minimization.
Despite its power, FEA remains constrained by computational demands,
mesh quality challenges, modeling simplifications, and the need for high-
quality input data
In summary, FEA significantly enhances the efficiency and precision
of metal forming. When applied critically—validating models, carefully
setting boundary conditions, and interpreting results—the method offers
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invaluable support in reducing development cycles, improving product
quality, and enabling smarter, data-driven engineering design.
References
• “Today the metal forming industry is making increasing use of simulation
… FEA is the most common method … to determine whether a proposed
design will produce parts free of defects such as fracture or wrinkling.”
Wikipedia
• “FEA helps identify areas of over-engineering… reduces development
time and costs associated with building and testing multiple prototypes.”
ETA, Inc.
• “FE simulations are often required to reduce the experimental cost and
time by reducing number of trials in the product development cycle…
optimizing, planning and simulating of forming processes becomes more
and more important.” ijmer.com
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