Abstract: An adaptive EFG-FE coupling method is proposed and developed for the numerical simulation of lateral extrusion and forward-backward extrusion. Initially, the simulation has been implemented by using a conventional FE model. During the deforming process, mesh quality is checked at every incremental step. Distorted elements are automatically converted to EFG nodes, whereas, the less distorted elements are reserved. A new algorithm to generate EFG nodes and interface elements is presented. This method is capable of dealing with large deformation and has higher computational efficiency than using an EFG method wholly. Numerical results demonstrate that the adaptive EFG-FE coupling method has reasonable accuracy and is effective for local bulk metal forming such as extrusion processes.

Key words: Meshless method, Coupling method, Numerical simulation, Extrusion process