Physical Modeling of Metalworking Processes—II: Comparison of Visioplastic Modeling and Computer Simulation

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The analytical modeling of physical processes is an integral part of scientific and technical research. Physical build-and-test procedures used for designing forging dies are prohibitively expensive and result in long lead times in obtaining satisfactory designs. In the present study the wedge test was advanced to the level of a standard laboratory test in order to verify the analytical results of a viscoplastic finite-element program, ALPID (Analysis of Large Plastic Incremental Deformation), which was developed to simulate the metal flow in deformation processes such as forging and extrusion. Wedge-shaped specimens were machined from plates of 1100-F and 6061-T6 aluminum alloy and the grids engraved on the meridian plane by means of a CNC engraver. The specimens were compressed in segmented dies at room temperature. The undeformed and deformed grids were digitized, and the true effective strains were calculated using a computer program developed for that purpose. The effective strains were then displayed as contour plots for comparison with the ALPID-generated strain values. Comparison of the experimental and ALPID results indicates that the values predicted by the ALPID code are very near the experimental values. The minor differences in the results are attributed to unavoidable experimental errors.