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This article presents an efficient pseudo-inverse approach for the damage prediction in cold forging process simulation. Pseudo-inverse approach combines the advantages of the fast inverse approach and accurate incremental approaches. Some intermediate configurations are created geometrically and corrected mechanically to well describe the deformation path. The formulation of an axi-symmetrical element based on pseudo-inverse approach is presented. A strain-based damage model is introduced in the flow theory of plasticity. A direct scalar integration algorithm of plasticity-damage is developed, leading to a fast and robust algorithm for large strain increments. The cold forging processes of two axi-symmetrical parts are simulated to validate pseudo-inverse approach by the incremental approach ABAQUS/Explicit. Pseudo-inverse approach gives very good results, but uses much less CPU time. [ABSTRACT FROM PUBLISHER]

Abstract: This paper presents a new simplified method called “Pseudo Inverse Approach” (PIA) for the axi-symmetrical cold forging modeling. The PIA keeps the advantages of the Inverse Approach (very fast) but gives good stress estimation by taking into account the loading history. Some intermediate configurations are created by using a free surface method to consider the deformation paths without contact treatment. A new direct algorithm of plasticity is developed leading to a fast and robust plastic integration procedure for very large strain increments. The PIA results are compared to those obtained by using ABAQUS software to show the efficiency and limitations of the PIA. [Copyright &y& Elsevier]