Finite element modeling of multi-object manufacturing processes is presented with supporting experiments. The underlying finite element implementation is based on the flow formulation and further coupled with thermal and electrical models to accomplish electro-thermo-mechanical simulation. All three models are implemented with contact algorithms that can take care of the interactions between multiple objects. Focusing on the mechanical aspects, this presentation includes simulations and experiments designed for testing mechanical contact between plastically deforming parts of similar and dissimilar materials. While being plastically deformed against each other under increasing forging load, the parts dynamically develop their mutual contact interfaces. Comparisons of the final geometry as well as force-displacement curves are evaluated. The potential of simulated applications are discussed for the purpose of joining technologies involving plastic deformation and contact.
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6th International Seminar on Precision Forging, 2013