The forging process is simulated using a 2-D axisymmetric model meshed with a 2-D four-node structural solid element (PLANE182). The model represents an elastoplastic cylindrical block (the work piece) sitting in a rigid surface (static die).

The block is deformed by another rigid surface (moving die) that moves at an infinitesimal speed, such that the final shape of the work piece becomes a ring gear with complete die fill.

The initial analysis diverges due to excessive mesh distortion when 96 percent of the total loading (TIME = 0.96) is reached.

The initial rezoning is applied using Nonlinear Adaptive Region technology, and the entire work piece is remeshed. The analysis continues with the new mesh and converges to completion, but the mesh is severely distorted.

The results of effective plastic strains and total strains can be compared with results of a similar problem [1].