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In this paper, a fully adaptive 3D numerical methodology based on a tetrahedral element was proposed in order to improve the finite element simulation of any metal forming process. This automatic methodology was implemented in a computational platform which integrates a finite element solver, 3D mesh generation and a field transfer algorithm. The proposed remeshing method was developed in order to solve problems associated with the severe distortion of elements subject to large deformations, to concentrate the elements where the error is large and to coarsen the mesh where the error is small. This leads to a significant reduction in the computation times while maintaining simulation accuracy. In addition, in order to enhance the contact conditions, this method has been coupled with a specific operator to maintain the initial contact between the workpiece nodes and the rigid tool after each remeshing step. In this paper special attention is paid to the data transfer methods and the necessary adaptive remeshing steps are given. Finally, a numerical example is detailed to demonstrate the efficiency of the approach and to compare the results for the different field transfer strategies. [ABSTRACT FROM AUTHOR]

Forming processes usually involve irreversible plastic transformations. The calculation in that case becomes cumbersome when large parts and processes are considered. Recently Model Order Reduction techniques opened new perspectives for an accurate and fast simulation of mechanical systems. In some processes, plastic deformations remain very localized, for example in the immediate neighborhood of the surface. In that case, the in-plane characteristic dimension is several orders of magnitude higher than the one related to the deepness in which plasticity localizes. In those situations the use of standard mesh-based 3D discretization is challenging because the extremely different characteristic dimensions that to capture all the information requires the use of millions of nodes. [ABSTRACT FROM AUTHOR]