Incremental bulk deformation processes have traditionally been difficult to simulate. This paper will argue that, despite advances in computation and software, they remain difficult to model. The main reason for this is the shortage of ideas on what is the real objective of FE modelling for such processes. Even a very detailed model and data obtained in simulation does not give answers to the main question - how to optimise the process parameters? High computational time and volume of information only aggravate the situation. All modern mathematical techniques of dimensionality reduction (such as POD/PGD) lose their power when the priorities and acceptable compromises of modelling are not clear. This paper tries to use a large volume of available experimental and modelling experience to illustrate this problem and look for possible break-through directions.
- flow forming
- process modelling
- rotary forging
- simplification approaches. Introduction