The study is concerned with the finite element analysis of two-dimensional cold forging processes by using the modular remeshing technique and the expert system which has been developed in the framework of the proposed modular remeshing scheme. In most of practical forging processes, a systmatic method of remeshing is required due to 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, a proper design of meshes plays the importent role in the analysis. In so-called Modular Remeshing", the physical characteristics of metal flow and geometric characteristics are incorporated in a "Module", which can be applied to the mesh design for a certain mode of deformation in so far as the topology of deforming region remains the same. For the purpose of more effective and systematic use of the modular remeshing scheme, an expert system has been developed for decision making for module type, control point and module parameters. The developed system consists of a knowledge base and an inference engine and a user interface. If the deformation mode is included in the knowledge base, the mesh for the computational region is generated automatically. The user is allowed to do the interactive job in a graphic terminal as well. In order to show the effectiveness of the method, the rib-web type forging with axial or radial relief and spike forging are simulated by using the developed modules and the knowledge base for modes of deformation. It has been thus shown that the proposed method of automatic remeshing by using modular remeshing and expert system can be futher extended and applied to a variety of forging problems with complicated geometrical configurations.
