Adaptive Finite Element Methods for Unsteady Lubricated Metal Forming Processes

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9300675 Liu One graduate student at Northwestern University will be supported to develop adaptive multiple scale methods for the design and rapid prototyping of metal forming processes is requested. Computer simulation methods for metal forming processes based on Arbitrary Lagrangian-Eulerian (ALE) finite elements, adaptive mesh deployment techniques, multiple-scale methods, and hydrodynamic lubrication finite elements will be developed. In particular it is planned to emphasize the interaction of the tool and mental work piece by including the effects of lubricant flow, pressure gradient, film entraiment, surface roughness and sliding. This will provide a more realistic modeling of contact, lubrication, and frictional stresses. In the research program, these aspects will be studied in conjuction with computer simulation of metal forming processes. Simulation results will be compared with available experimental data to help validate and improve the theoretical models.