The study is concerned with finite element analysis of two-dimensional cold forging processes by using the modular remeshing technique. In most of the practical forging processes, a systematic method of remeshing is required due to the severe mesh distortion after some finite deformation when using the finite element analysis. In order to cope with the problem of mesh degeneracy during deformation, the proper design of meshes plays the most important role in the analysis.
In so-called "Modular remeshing", the physical characteristics of metal flow and the geometric characteristics are incorporated in a "Module", which can be applied to a certain mode of deformation in so far as the topology of deforming region remains the same. Some useful kinds of modules have been developed and a systematic method of global construction op modules is suggested. In the scheme the computational region is divided into several modules. In order to show the effectiveness of the method forging of a turbine blade and a webbed blank is simulated by using the proposed modules. As compared with the conventional remeshing scheme with regular or quasi-regular structure of modules, modular remeshing has been shown to reduce the computation time drastically with sufficient computational accuracy. It has been thus shown that the proposed method of modular remeshing can be extended and applied to a variaty of forging problems with complicated geometric natures.