Lagrangian formulation and numerical simulation of multiphysics models. Application to electric upsetting

Abstract

Forming processes are fundamental in modern industry, as they enable the permanent deformation of a workpiece into a desired geometry while preserving cohesion and mass. Compared with casting or machining, forming offers advantages such as low material waste, short production times, precise final shapes, and improved mechanical properties. Nevertheless, it also demands high forces, costly equipment, and faces limitations with complex geometries. Conventional bulk and sheet forming techniques, which primarily rely on mechanical contact, are widely used but remain challenged by high cost, energy consumption, and environmental impact. To address demands for lighter components, higher precision, and greater sustainability, energy-assisted forming methods have been developed. These include electromagnetic forming, which employs Lorentz forces; ultrasonic-assisted forming, which reduces friction and resistance through vibrations; and electrically assisted forming, which lowers deformation resistance by Joule heating.