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This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

Implicit and explicit time integration schemes in conjunction with the finite element method are presented for the transient response of highly non‐linear problems such as impact situations exhibiting important material dissipation. Surprisingly the implicit schemes lead to excellent convergence properties that make them a cost‐efficient alternative to explicit scheme generally advocated as the best choice for these problems. As numerical illustrations, we present here the academic impact between two flexible bodies, a long tube and a long plate, as well as a more industrial‐oriented application: the impact between a fan blade and a double casing.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

Parameter identification is a technique which aims at determining material or other process parameters based on a combination of experimental and numerical techniques. In recent years, heuristic approaches, such as genetic algorithms (GAs), have been proposed as possible alternatives to classical identification procedures. The present work shows that particle swarm optimization (PSO), as an example of such methods, is also appropriate to identification of inelastic parameters. The paper aims to discuss these issues.

PSO is a class of swarm intelligence algorithms which attempts to reproduce the social behaviour of a generic population. In parameter identification, each individual particle is associated to hyper-coordinates in the search space, corresponding to a set of material parameters, upon which velocity operators with random components are applied, leading the particles to cluster together at convergence.

PSO has proved to be a viable alternative to identification of inelastic parameters owing to its robustness (achieving the global minimum with high tolerance for variations of the population size and control parameters), and, contrasting to GAs, higher convergence rate and small number of control variables.

PSO has been mostly applied to electrical and industrial engineering. This paper extends the field of application of the method to identification of inelastic material parameters.

The total Lagrangian formulation and implementation of the element‐free Galerkin method (EFG) is presented for the analysis of contact‐impact problems with large deformations and for the simulation of metal forming processes. An integration scheme based on stress points is used, so no mesh is needed. A simple but general contact searching algorithm is used to treat the contact interface and an algorithm for the contact force is presented. Numerical results for Taylor bar impact are compared to finite element solutions and agree well. Solutions to upsetting, extrusion of metals with large material distortions are given to show the effectiveness of the algorithm. In particular, EFG is shown to be more capable of treating motions of the workpiece around corners of the punch than finite element methods.

The arbitrary Lagrangian—Eulerian (ALE) formulation, which is already well established in the hydrodynamics and fluid‐structure interaction fields, is extended to materials with memory, namely, non‐ linear path‐dependent materials. Previous attempts to treat non‐ linear solid mechanics with the ALE description have, in common, the implicit interpolation technique employed. Obviously, this implies a numerical burden which may be uneconomical and may induce to give up this formulation, particularly in fast‐transient dynamics where explicit algorithms are usually employed. Here, several applications are presented to show that if adequate stress updating techniques are implemented, the ALE formulation could be much more competitive than classical Lagrangian computations when large deformations are present. Moreover, if the ALE technique is interpreted as a simple interpolation enrichment, adequate—in opposition to distorted or locally coarse—meshes are employed. Notice also that impossible computations (or at least very involved numerically) with a Lagrangian code are easily implementable in an ALE analysis. Finally, it is important to observe that the numerical examples shown range from a purely academic test to real engineering simulations. They show the effective applicability of this formulation to non‐linear solid mechanics and, in particular, to impact, coining or forming analysis.

Gives a bibliographical review of the error estimates and adaptive finite element methods from the theoretical as well as the application point of view. The bibliography at the end contains 2,177 references to papers, conference proceedings and theses/dissertations dealing with the subjects that were published in 1990‐2000.

Purpose – The aim of this work is to provide a global 3D finite element (FE) model devoted to the modelling of superficial soil ploughing in the large deformation range and for a vast class of soil treatment tools. Design/methodology/approach – We introduced soil constitutive equation in a FE software initially designed for the metal forming. We performed the numerical integration of the non‐linear ploughing problem. Non‐linearities encountered by the problem can be summed up: as soil constitutive equation (idealized with non‐associated compressible plastic law), unilateral frictional contact conditions (with a rigid body), geometrical non‐linearities (the ploughing tool) and large deformation range. To handle such difficulties we performed several numerical methods as implicit temporal scheme, Newton‐Raphson, non‐symmetric iterative solver, as well as proper approximation on stress and strain measures. Findings – Main results deal with the validation of the integration of the non‐linear constitutive equation in the code and a parametric study of the ploughing process. The influence of tool geometric parameters on the soil deformation modes and on the force experienced on the tools had been point out. As well, the influence of soil characteristics as compressibility had been analyzed. Research limitations/implications – This research is devoted to perform a numerical model applicable for a large range of soil treatment tools and for a large class of soil. However, taking into account all kind of soil is utopist. So limitations met are essentially related to the limit of the accuracy of the elasto‐plastic idealization for the soil. Practical implications – In practice the numerical model exposed in the paper can clearly help to improve and optimize any process involving superficial soil submitted to the mechanical action of a rigid body. Originality/value – The original value of the paper is to provide a global and an applicable numerical model able to take into account the main topics related to the ploughing of superficial soils. Industrials in geotechnics, in agriculture or in military purposes can benefit in using such numerical model.

Discusses an alternative formulation for the incremental determination of stresses in strain measures that can be used to replace the stress rates currently employed. The formulation is based on Doyle‐Hill generalized definition of strain, the corresponding conjugate stresses and an isotropic hyperelastic constitutive equation. When used to analyze the simple shear deformation, the proposed formulation avoids the pathologies usually observed (oscillations, pressure build up, path dependence). The origin and importance of these pathologies is then discussed in relation to different materials behavior. It is shown that the incremental procedure used together with the logarithmic definition of strain is the most convenient, but that other approximations may be used in well defined particular situations. The numerical algorithms proposed are detailed in an Appendix.

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.