Table of Contents
International Journal of Manufacturing Engineering
Volume 2014 (2014), Article ID 385065, 15 pages
Research Article

Failure Prediction in Bulk Metal Forming Process

Department of Mechanical Engineering, International Islamic University Malaysia, Jalan Gombak, 53100 Kuala Lumpur, Malaysia

Received 25 August 2014; Accepted 13 October 2014; Published 10 November 2014

Academic Editor: Hailiang Yu

Copyright © 2014 Ameen Topa and Qasim H. Shah. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


An important concern in metal forming is whether the desired deformation can be accomplished without defects in the final product. Various ductile fracture criteria have been developed and experimentally verified for a limited number of cases of metal forming processes. These criteria are highly dependent on the geometry of the workpiece and cannot be utilized for complicated shapes without experimental verification. However, experimental work is a resource hungry process. This paper proposes the ability of finite element analysis (FEA) software such as LS-DYNA to pinpoint the crack-like flaws in bulk metal forming products. Two different approaches named as arbitrary Lagrangian-Eulerian (ALE) and smooth particle hydrodynamics (SPH) formulations were adopted. The results of the simulations agree well with the experimental work and a comparison between the two formulations has been carried out. Both approximation methods successfully predicted the flow of workpiece material (plastic deformation). However ALE method was able to pinpoint the location of the flaws.