Numerical Simulation of Double Cup Extrusion Test Using the Arbitrary Lagrangian Eulerian Formalism

In this chapter Double Cup Extrusion Test (DCET) is modelled using the finite element method with the help of the Arbitrary Lagrangian Eulerian (ALE) formalism. DCET is a tribological test involving very large deformations which are traditionally dealt with complicated and costly remeshing algorithms. Since the topology of ALE meshes should remain constant throughout the simulation, twovery thin layers of auxiliary elements are added to the initial mesh of the billet where the material is expected to flow. This numerical trick is combined with an original and efficient node relocation procedure which allows the model to take into account complex geometries of punches. The presented model is firstly validated for limited punch strokes thanks to a purely Lagrangian simulation. It is then compared with results from the literature. Eventually the general nature and the effectiveness of this numerical strategy is demonstrated by a fully-coupled thermomechanical simulation of thixoforming where the final shape of the billet is compared to experimental measurements.