Buried pipeline networks play a vital role in the transportation of oil and natural gas from centers of production to centers of consumption. A common manufacturing technique for such pipes is the UOE process, where a flat steel plate is first formed into a U shape, then into an O shape, welded at the seam, and mechanically expanded before being shipped on site. The UOE forming process deforms the pipe material plastically and induces residual strains in the pipe. Such pipes are commonly buried on side and then are pressurized under the high head of the fluids they convey which induce hoop stresses as high as 80% of the pipe yield strength. When buried pipelines cross the regions of discontinuous permafrost, they undergo differential frost heaving, inducing significant bending deformations, which potentially induce local buckling in the pipe wall. To control local buckling, design standards impose threshold limits on buckling strains. Such threshold values are primarily based on costly full-scale experimental results. Past nonlinear finite element analysis attempts aiming at determining the threshold buckling strains have neglected the presence of residual stresses induced by the UOE forming and were thus found to grossly overestimate the buckling strains compared to those based experiments. Within the above context, the present study focuses on developing a numerical technique to predict the residual stresses induced during UOE forming, and incorporating the induced residual stresses in 3D nonlinear FEA modeling to more reliably predict buckling strain limits. Comparisons with conventional analysis techniques that omit residual stresses reveal the importance of incorporating residual stresses induced in forming when quantifying buckling strains.

Für die Herstellung von Kunststoffformteilen, z.B. Verpackungen, Komponenten für Haushaltsgeräte, Automobil- oder Medizinbranche, werden aufgrund von Mikrostrukturen, neuen sowie hybriden Materialien und dem zunehmenden Kostendruck steigende Anforderungen an das Formteil, das Verfahren und den Prozess gestellt. Entsprechende Technologien zur Verbesserung des Umformprozesses stehen vor der Markteinführung oder werden derzeit entwickelt. Aufgrund des damit einhergehenden Anstiegs der Technologiekomplexität werden zunehmend Material- und Prozessmodelle eingesetzt. Die dienen der Technologieentwicklung, der Optimierung des Prozesses und bilden eine Hilfestellung bei der Inbetriebnahme. Ein Schwerpunkt und eine Herausforderung ist dabei die Materialmodellierung. Während des Umformens ins Werkzeug beim Thermoformen treten verschiedene Effekte auf: z. B. Dehnung und Verschiebung der Polymerketten, Bildung von amorphen und kristallinen Strukturen. Das sich daraus ergebende Verhalten ist durch geeignete Materialmodelle und deren Parametrisierung abzubilden. Ein gängiger Ansatz zur Bestimmung des Materialverhaltens und die damit verbundene Bestimmung der Materialparameter ist die Reverse-Engineering-Methode. Zu diesem Zweck stehen verschiedene Ersatzversuche zur Auswahl, z.B. Membrane-Inflation- Rheometer (MIR), Thermoformen-Material-Charakterisierung (TMC) und uniaxiale sowie biaxiale Zugversuche. Mit Hilfe geeigneter Modelle werden die Parameter entsprechend der experimentellen Daten gefittet. Für die Abbildung des Umformprozesses in einem numerischen Modell ist die Implementierung des Materialmodells in ein Prozessmodell notwendig. Um quantitative und qualitative Aussagen zur Übereinstimmung des numerischen Modells mit dem tatsächlichen Umformprozess zu erhalten, ist stets eine Validierung notwendig, indem experimentelle Simulationen durchgeführt und anhand ausgewählter Zielgrößen analysiert und den numerischen Ergebnissen gegenübergestellt werden. Zu diesem Zweck stehen verschiedene neue Messmethoden zur Verfügung, z.B. GEWAND, OCT, Hall-Effekt-Dickenmesser.

O atrito na interface entre a peça e a ferramenta tem considerável importância em operações de estampagem de chapas, são necessários conhecimentos precisos sobre processos de conformação de chapas para a análise e projeto de novas peças e ferramentas, assim como para validação de uma simulação numérica. Este trabalho usa o método de determinação do coeficiente de atrito em estampagem através do ensaio de dobramento sob tensão e avalia sua precisão com o uso do software de elementos finitos LS-DYNAFORM, específico para esse processo de fabricação. Como existem seis equações que calculam o coeficiente de atrito para o mesmo ensaio de dobramento sob tensão, foram testadas todas as equações com o objetivo de verificar se existe variação entre os resultados. O material de estudo foi o alumínio comercialmente puro, liga AA1100. Os resultados indicam que há certa variação para cada equação usada, principalmente para aquelas que consideram o torque no pino. É observada também uma tendência do software a se distanciar dos resultados práticos por considerar o atrito como uma constante ao longo do processo. A pressão de contato entre o pino e a chapa no ensaio de dobramento sob tensão também foi avaliada através de um filme que tem a capacidade de registrar a pressão aplicada juntamente com a medição da força vertical aplicada ao pino. Os resultados indicam que a força vertical é mais precisa para se definir a pressão de contato ao uso de equações pré-estabelecidas e que a área de atuação da chapa no pino é sempre menor que a área calculada geometricamente. Por fim, para se saber qual é o comportamento do atrito para altas pressões, o ensaio de dobramento sob tensão foi feito com força variável e constatou-se que o atrito diminui com o aumento das pressões. No entanto, os valores iniciais da curva de atrito versus pressão de contato não foram obtidos pois nesse caso seria necessário usar uma máquina diferente da usada nesse estudo, ou seja, que não use pressão de óleo para acionamento e movimentação da chapa. / Friction at the interface of workpiece and tooling has a considerably importance in sheet metal forming operations. It is necessary an accurate knowledge for the analysis and design of new workpieces and tooling, as well as for the validation of a numeric simulation. This work uses the bending under tension test to determining the friction coefficient in sheet metal forming and evaluates its accuracy using the finite element software LS-DYNAFORM, specific to this manufacturing process. Since there are six equations that calculate the coefficient of friction for the same bending under tension test, all equations were tested in order to verify if there is much variation between the results. The material used in these work was pure commercial aluminum alloy AA1100. The results indicate that there is some variation for each equation used, especially for those that consider the torque on the pin. It was also observed a tendency for software to distance themselves from practical results considering friction as a constant throughout the process. It is also observed a tendency for the software to generate curves away from the tests as the friction increases. The contact pressure between the pin and the sheet in the bending under tension test was also evaluated through a film that has the ability to measure the pressure applied, together with the measurement of the vertical force applied to the pin. The results indicate that the vertical force is more accurate to define the contact pressure than equations previously established for this and that the contact area between the sheet and the pin is always smaller than the area calculated geometrically. Finally, to know the behavior of the friction at high pressures, the bending under tension test was done with variable forces and it was found that the friction decreases with increasing the pressure, which is in full agreement with the theory.

L'objectif de ce travail de thèse est de proposer un modèle numérique permettant de simuler la mise en forme de viroles métalliques par un procédé de formage incrémental. Ce procédé de mise en forme est particulièrement intéressant pour les industriels car il permet d'une part de réduire les pertes de matière première et d'autre part d'obtenir des pièces avec des propriétés mécaniques améliorées. La mise au point du procédé reste néanmoins une étape fastidieuse et le recours à l'outil numérique devient indispensable si l'on souhaite atteindre le meilleur rapport qualité/coût-délai. À cette fin, le comportement mécanique d'un acier faiblement allié a été étudié à travers divers essais de traction et de cisaillement. Les résultats de ces essais mettent en évidence que le matériau présente une faible anisotropie de comportement, une faible sensibilité à la vitesse de déformation et un écrouissage cinématique (effet Bauschinger). Cette base de données expérimentales a ensuite servi à l'identification de plusieurs modèles de comportement élastoplastique phénoménologique. Deux modèles numériques différents ont alors été développés au sein du code de calculs par éléments finis Abaqus afin de simuler le formage d'une pièce de référence et d'une étude de cas industriel. Les résultats de ces simulations montrent que le modèle tridimensionnel fournit une bonne représentation du procédé de formage a contrario du modèle bidimensionnel axisymétrique construit notamment afin de réduire les temps de calculs. Par ailleurs, une étude de la sensibilité du modèle éléments finis aux différents modèles de comportement identifiés a été menée. Les résultats de cette étude ont permis de mettre en évidence que la description du comportement plastique n'a qu'une faible influence sur la géométrie de la pièce déformée alors même que le comportement élastique joue un rôle bien plus important notamment au regard du calcul du retour élastique des pièces. Il a également été montré que le choix d'une forme particulière de géométrie de pièce permettait de réduire considérablement ce phénomène. Enfin, une étude sur la modélisation du comportement du matériau avec un modèle moins phénoménologique a été entreprise. Elle permet d'avoir un caractère plus générique avec un nombre de paramètres inférieurs aux modèles phénoménologiques en considérant les hétérogénéités du matériau. Elle ouvre la voie à l'utilisation de modèle de comportement prenant en compte des phénomènes physiques au sein d'un modèle éléments finis sur une opération de formage. / This Ph.D. thesis aims to propose a numerical model for modelling the incremental forming process of a metallic thin wall short tube. This process is especially interresting for manufacturer because it allows to reduce the material raw losses and to increase the mechanical properties of the part. The technical development of the process is a tedious step and the numerical simulation becomes necessary if the best ratio quality/cost-delay must be reach. To achieve this goal, the mechanical behaviour of a low-allow steel was studied with uniaxial and shear tests. The results of this tests highlight that the material has a low anisotropic behaviour, a low strain rate sensitivity and kinematic hardening (Bauschinger effect). Then, this experimental database was used to identify several elastic-plastic phenomenological behaviour laws. Two different numerical models were developed in the finite element code Abaqus to simulate the forming of a reference part and an industrial study. Results of simulation show that tridimensional model is a good representation of the forming process contrary to the bidimensional model built to reduce the CPU time. Furthermore, a finite element model sensibility study of the identifying behaviour models has been carried out. The results of this study highlight that plastic behaviour description has a low influence on the formed part geometry. However, the elastic behaviour has an important influence in particular on the calculated springback. Moreover, it was shown that the choice of a particular part geometry reduce in an important way this phenomenon. Finaly, a study about the material behaviour modeling with a less phenomenological model was done. This latter is a more generic model with a lower parameters number compared with phenomenological models taking into account material heterogeneities. This study innovates for the behaviour model taking account of physical phenomenon in finite elements model on a forming process.

O atrito na interface entre a peça e a ferramenta tem considerável importância em operações de estampagem de chapas, são necessários conhecimentos precisos sobre processos de conformação de chapas para a análise e projeto de novas peças e ferramentas, assim como para validação de uma simulação numérica. Este trabalho usa o método de determinação do coeficiente de atrito em estampagem através do ensaio de dobramento sob tensão e avalia sua precisão com o uso do software de elementos finitos LS-DYNAFORM, específico para esse processo de fabricação. Como existem seis equações que calculam o coeficiente de atrito para o mesmo ensaio de dobramento sob tensão, foram testadas todas as equações com o objetivo de verificar se existe variação entre os resultados. O material de estudo foi o alumínio comercialmente puro, liga AA1100. Os resultados indicam que há certa variação para cada equação usada, principalmente para aquelas que consideram o torque no pino. É observada também uma tendência do software a se distanciar dos resultados práticos por considerar o atrito como uma constante ao longo do processo. A pressão de contato entre o pino e a chapa no ensaio de dobramento sob tensão também foi avaliada através de um filme que tem a capacidade de registrar a pressão aplicada juntamente com a medição da força vertical aplicada ao pino. Os resultados indicam que a força vertical é mais precisa para se definir a pressão de contato ao uso de equações pré-estabelecidas e que a área de atuação da chapa no pino é sempre menor que a área calculada geometricamente. Por fim, para se saber qual é o comportamento do atrito para altas pressões, o ensaio de dobramento sob tensão foi feito com força variável e constatou-se que o atrito diminui com o aumento das pressões. No entanto, os valores iniciais da curva de atrito versus pressão de contato não foram obtidos pois nesse caso seria necessário usar uma máquina diferente da usada nesse estudo, ou seja, que não use pressão de óleo para acionamento e movimentação da chapa. / Friction at the interface of workpiece and tooling has a considerably importance in sheet metal forming operations. It is necessary an accurate knowledge for the analysis and design of new workpieces and tooling, as well as for the validation of a numeric simulation. This work uses the bending under tension test to determining the friction coefficient in sheet metal forming and evaluates its accuracy using the finite element software LS-DYNAFORM, specific to this manufacturing process. Since there are six equations that calculate the coefficient of friction for the same bending under tension test, all equations were tested in order to verify if there is much variation between the results. The material used in these work was pure commercial aluminum alloy AA1100. The results indicate that there is some variation for each equation used, especially for those that consider the torque on the pin. It was also observed a tendency for software to distance themselves from practical results considering friction as a constant throughout the process. It is also observed a tendency for the software to generate curves away from the tests as the friction increases. The contact pressure between the pin and the sheet in the bending under tension test was also evaluated through a film that has the ability to measure the pressure applied, together with the measurement of the vertical force applied to the pin. The results indicate that the vertical force is more accurate to define the contact pressure than equations previously established for this and that the contact area between the sheet and the pin is always smaller than the area calculated geometrically. Finally, to know the behavior of the friction at high pressures, the bending under tension test was done with variable forces and it was found that the friction decreases with increasing the pressure, which is in full agreement with the theory.

O atrito na interface entre a peça e a ferramenta tem considerável importância em operações de estampagem de chapas, são necessários conhecimentos precisos sobre processos de conformação de chapas para a análise e projeto de novas peças e ferramentas, assim como para validação de uma simulação numérica. Este trabalho usa o método de determinação do coeficiente de atrito em estampagem através do ensaio de dobramento sob tensão e avalia sua precisão com o uso do software de elementos finitos LS-DYNAFORM, específico para esse processo de fabricação. Como existem seis equações que calculam o coeficiente de atrito para o mesmo ensaio de dobramento sob tensão, foram testadas todas as equações com o objetivo de verificar se existe variação entre os resultados. O material de estudo foi o alumínio comercialmente puro, liga AA1100. Os resultados indicam que há certa variação para cada equação usada, principalmente para aquelas que consideram o torque no pino. É observada também uma tendência do software a se distanciar dos resultados práticos por considerar o atrito como uma constante ao longo do processo. A pressão de contato entre o pino e a chapa no ensaio de dobramento sob tensão também foi avaliada através de um filme que tem a capacidade de registrar a pressão aplicada juntamente com a medição da força vertical aplicada ao pino. Os resultados indicam que a força vertical é mais precisa para se definir a pressão de contato ao uso de equações pré-estabelecidas e que a área de atuação da chapa no pino é sempre menor que a área calculada geometricamente. Por fim, para se saber qual é o comportamento do atrito para altas pressões, o ensaio de dobramento sob tensão foi feito com força variável e constatou-se que o atrito diminui com o aumento das pressões. No entanto, os valores iniciais da curva de atrito versus pressão de contato não foram obtidos pois nesse caso seria necessário usar uma máquina diferente da usada nesse estudo, ou seja, que não use pressão de óleo para acionamento e movimentação da chapa. / Friction at the interface of workpiece and tooling has a considerably importance in sheet metal forming operations. It is necessary an accurate knowledge for the analysis and design of new workpieces and tooling, as well as for the validation of a numeric simulation. This work uses the bending under tension test to determining the friction coefficient in sheet metal forming and evaluates its accuracy using the finite element software LS-DYNAFORM, specific to this manufacturing process. Since there are six equations that calculate the coefficient of friction for the same bending under tension test, all equations were tested in order to verify if there is much variation between the results. The material used in these work was pure commercial aluminum alloy AA1100. The results indicate that there is some variation for each equation used, especially for those that consider the torque on the pin. It was also observed a tendency for software to distance themselves from practical results considering friction as a constant throughout the process. It is also observed a tendency for the software to generate curves away from the tests as the friction increases. The contact pressure between the pin and the sheet in the bending under tension test was also evaluated through a film that has the ability to measure the pressure applied, together with the measurement of the vertical force applied to the pin. The results indicate that the vertical force is more accurate to define the contact pressure than equations previously established for this and that the contact area between the sheet and the pin is always smaller than the area calculated geometrically. Finally, to know the behavior of the friction at high pressures, the bending under tension test was done with variable forces and it was found that the friction decreases with increasing the pressure, which is in full agreement with the theory.

In the initial stage, the sample preparation was done by using the techniques of Anodic etching and anodic forming processes where a repeated trial and error method of sample preparation headed towards making out a suitable sample set for characterization. After this step, the set of 2 different industrial samples were introduced and anodic oxide forming process was carried out in different electrolytes.    In the sample preparations, 4 different electrolytes were used 15% wt. Ammonium Adiphate, 1.5% wt. Ammonium Phosphate, 7% wt. Boric acid and 15% Penta Borate at different stages for performing the anodic oxide forming process. Minimum forming voltages of 20V to a maximum of 100V was employed in the sample preparation and to overcome the waiting time in forming the etched samples a higher current of 0.5A was used.   After the samples preparation, Electrochemical Impedance spectroscopy was used as a tool for characterising the various groups of samples and for observing the micro structures of various samples, they were fractured and the observed on the cross section by SEM.   After the analysis of the etched samples was made, an attempt to compare the results of the data of these samples to that of the 2 set of industrial samples was made and found that the resultant data wasn’t stable enough to characterize since huge scattering were occurring and whereby the simulation of the CPE circuit for the chosen circuit in the analysis was not possible.   Under the analysis, a randomly chosen industrial sample was also used and the resultant data was utilised in understanding the response of the system to different electrolytes. / Sammanfattning   Avhandlingsarbetet har genomförts på KEMET AB i samarbete med yttekniklaboratoriet vid JTH i syfte att karakterisera den etsade anodiska aluminiumfolien som grundprov med anodisering och etsning för ytbehandling.   I inledningsskedet gjordes provberedningen med användning av teknikerna för anodisk etsning och anodbildande processer där en upprepad provnings- och felmetod för provberedning ledde ut mot att utarbeta en lämplig provuppsättning med avseende på karakterisering. Efter detta steg infördes uppsättningen av 2 olika industriella prover och anodoxidbildande process utfördes i olika elektrolyter.   I provpreparaten användes 4 olika elektrolyter 15 % vikt Ammoniumadiphat, 1,5 vikt% Ammoniumfosfat, 7 vikt% Borsyra och 15 % Penta-borat vid olika steg för utförande av anodoxidbildningsförfarandet. Minimala formningsspänningar på 20V till ett maximum av 100V användes i provframställningen och för att övervinna väntetiden vid bildning av de etsade proven användes en högre ström av 0,5A.   Efter provberedningen användes elektrokemisk impedansspektroskopi som ett verktyg för att karakterisera de olika grupperna av prover och för att observera mikrostrukturerna i olika prover, de bröts och de observerades i tvärsnittet av SEM.   Efter att analysen av de etsade proverna gjordes ett försök att jämföra resultaten av data från dessa prover till den för de två uppsättningarna av industriella prover. Det är konstaterat att de resulterande data inte var stabila nog att karakterisera eftersom stor spridning inträffade och varigenom simuleringen av CPE-kretsen för den valda kretsen i analysen inte var möjlig.   Under analysen användes också ett slumpmässigt valt industriellt prov och de resulterande data användes för att förstå systemets respons till olika elektrolyter.

The thesis focus on modelling of float glass making process using viscose film type approximation. Navier-Stokes equations are averaged over one spatial variable. Then the domain with an a priory unknown shape, where the shape is a part of the solution, is transformed to a fixed computational domain. The problem is solved by finite element method using FEniCS software. In the end is discussed an influence of several parameters such as wheels, which regulates thickness of the glass and enforce an inner condition, boundary conditions or spreading coefficient on the numerical result. 1

Oriented thermoplastics offer interesting opportunities for making structural automotive components due to their higher strengths. A new process, referred to as the axial feed hot oil tube forming (AF-HOTF) process, has been developed and studied for the forming of oriented thermoplastic tubes. The starting material for AF-HOTF process is an oriented polypropylene (OPP) tube produced by the solid state extrusion process. AF-HOTF was used to study forming and fracture behaviour of OPP tubes at large strains. Mechanical properties and molecular orientation of starting and post-formed materials were investigated to gain a better understanding of structure-property-process relationships during solid state extrusion and subsequent forming of OPP tubes. The development of molecular orientation and other microstructural changes and damage development in extruded and bulged OPP tubes during solid state extrusion and AF-HOTF processes were studied with optical microscopy, wide-angle X-ray diffraction (WAXD) and field emission scanning electron microscope (FE-SEM) techniques. Also, the development of large strains during AF-HOTF of OPP samples were experimentally studied in the form of spatial strain maps, strain/stress state and forming limit strains using an on-line strain mapping method based on digital image correlation (DIC). In addition, tensile tests have been carried out at room temperature on samples machined from the extruded and bulged tubes along the axial and hoop directions. Experimental quantitative relationships amongst molecular orientation parameters and extrusion and AF-HOTF process parameters such as draw ratio, strain and strain state have been obtained. These relationships in the form of White and Spruiell biaxial orientation factors provide a useful insight into molecular reorientation that occurs during extrusion and subsequent forming of OPP tubes. Also, an analytical model for forming limit prediction that takes into account OPP tube properties, tube dimensions and AF-HOTF process parameters was developed based on existing model of tube hydroforming in the literature. In addition, a new biaxial ball stretching test (BBST) system was developed and utilized to subject the thermoplastic tube to biaxial stretching. The design of the test-rig and results were presented for polypropylene (PP) tubes subjected to BBST at various temperatures. The BBST system was combined with an available on-line imaging and strain analysis system (ARAMIS® system from GOM) to observe the development of strains in the biaxial tensile region during the test. BBST samples were studied with wide angle X-ray diffraction (WAXD) pole figures. Three different hot forming processes (Solid-state extrusion, AF-HOTF and BBST) were used in this research. The structure of the extruded samples at draw ratio 5 and higher was completely changed to fibrils structure, and the yield strength and elastic modulus increased by 50%. Also the crystallinity increased from 47% to 68% with an increase in draw ratio. An increase in axial feed during the hot forming process resulted in higher formability (strains values of 0.55 major strain and -0.25 minor strain) and delayed failure. The analytical model prediction of bursting shows good agreement with the experimental results. The results provide an understanding of the orientation development in solid state extrusion of PP tubes as well as an understanding of tube formability, flow localization and fracture characteristics of PP tube from AF-HOTF process and other related processes. / Thesis / Doctor of Philosophy (PhD)

La compréhension des phénomènes thermiques et mécaniques mis en jeu lors de la mise en forme des matériaux est généralement réalisée avec l’aide de simulations numériques. Ces simulations montrent leurs limites pour les procédés qui conduisent à de très grandes déformations de la matière. Dans ce cas, de très fortes distorsions du maillage se produisent pendant le calcul, entrainant une augmentation de l’erreur, voire l’arrêt prématuré de la simulation. Cette étude porte sur le développement d’une stratégie de remaillage adaptative afin d’éviter les distorsions des éléments pendant les simulations en grandes transformations. La méthode proposée a été intégrée dans un environnement de calcul utilisant le solveur ABAQUS/Explicit, un mailleur 3D et un algorithme de transfert de champ.La méthode h-adaptative en combinaison avec un critère de contrôle basé sur l’endommagement et un estimateur d’erreur de type Zienkiewicz-Zhu Z2 (SPR-amélioré) ont été implantés. Le maillage initial est remplacé par un nouveau maillage avec le niveau de qualité désiré par l’utilisateur, tout en minimisant le nombre des degrés de liberté. Cette technique s’est montrée robuste et entièrement automatique pour déterminer la taille optimale des nouveaux éléments. Une fois le nouveau maillage généré, toutes les variables doivent être soigneusement transférées. Plusieurs techniques de transfert sont décrites et comparées. Des améliorations permettant d’augmenter leurs efficacités en termes de diffusion de l’information et de stabilité numérique ont été proposées. Une attention particulière est portée à la restauration de l'équilibre mécanique local du système. Les différentes techniques développées ont permis de modéliser différents procédés entrainant de grandes déformations élastoplastiques avec endommagement. Dans toutes les applications testées, il a été montré une amélioration de la précision et de la qualité des résultats numériques obtenus. Pour des opérations d’usinage, des mesures de champs cinématiques à travers la technique de corrélation d’images ont été réalisées afin de déterminer les champs de déformation en pointe d’outil. Ces mesures ont servi à la validation de la simulation numérique à l’échelle locale. La comparaison des champs cinématiques expérimentaux avec ceux issus du calcul éléments finis met en évidence la robustesse du processus d’adaptation du maillage proposée pour retranscrire les phénomènes locaux observés expérimentalement. En effet, la reproduction de l’écoulement de la matière sur les bords et la géométrie du copeau sont en très bonne corrélation avec les résultats expérimentaux. Ce développement a permis de proposer une description nouvelle du processus de formation des bandes de cisaillement. / In this work, a fully automated adaptive remeshing strategy, based on a tetrahedral element to simulate various 3D metal forming processes, was proposed. The aim of this work is to solve problems associated with the severe mesh distortion that occurs during the computation and which may be incompatible with the evolution of the physical behavior of the FE solution. Indeed, the quality of the mesh conditions affects the accuracy of the calculations. The proposed strategy is integrated in a computational platform which integrates a finite element solver (Abaqus/Explicit), 3D mesh generation and a field transfer algorithm.The base idea is to use the h-adaptive methodology in the combination with a damage-criterion error and Zienkiewicz-Zhu Z2 type error estimator (SPR-improved) to locally control the mesh modification-as-needed. Once a new mesh is generated, all history-dependent variables need to be carefully transferred between subsequent meshes. Therefore, different transfer techniques are described and compared. An important part of this work concerns the presentation of the proposed modification of the field transfer operator and a special attention is given to restore the local mechanical equilibrium of the system. During the large elasto-plastic deformation simulation with damage, the necessary steps for remeshing the mechanical structure are presented. The several types of applications are also given. For all studied applications, the above strategy can improve the accuracy and quality of numerical results. It also has benefits to decide how refined a mesh needs to be to reach a particular level of accuracy, or how coarse the mesh can be without unacceptably impacting solution accuracy.For the machining processes, kinematic field measurements using Digital image Correlation were performed to validate the numerical simulation at the local level. The comparison of the experimental kinematic fields and those resulting from the FE calculation highlights the robustness of the proposed mesh adaptation process which can transcribe the experimental local phenomena. Also, the reproduction of the material flow at the edges and the chip are correlated with the experimental results accurately. Finally, the physical study of the numerical results can be allowed to propose an innovative description of ASB formation.