Solid-state processing of metal material is a very complex physical and chemical process, which is coupled by a series of variations including heat transfer, momentum transfer, mass transfer, and phase change. Applying three-dimensional (3D) finite element numerical method to the simulation of solid-state processing can perform analysis of metal material’s forging processes before production trial production, can obtain their relevant information such as material flow law, temperature field, and strain field under the minimum physical test conditions, thereby predicting metal material’s forming defects and improving their forging quality. On the basis of summarizing and analyzing previous research works, this paper expounded the current status and significance of solid-state processing of metal materials, elaborated the development background, current status, and future challenges of 3D finite element numerical simulation, introduced the discrimination method and free surface solution method of numerical simulation calculation, conducted finite element model’s geometric assumptions, material selection, element division, model establishment, parameter selection, and initial and boundary condition determination, and simulated and analyzed rheological casting, remelting heating, thixoforming, and rotary piercing processes of metal materials. The results show that the 3D finite element numerical method can not only simulate various processes of flow field, temperature field, stress field, and microstructure in solid-state processing but also can provide a reliable basis for effectively obtaining a reasonable description and finding a more optimized design plan for metal material processing in a short time, which plays an important role in understanding and analyzing solid metal forming process, controlling and optimizing process parameters, guiding and mastering rheological casting, and secondary heating and rotary piercing of metal materials.

中文翻译：

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金属材料固态加工的三维有限元数值模拟与分析

金属材料的固态处理是一个非常复杂的物理和化学过程，其耦合有一系列变化，包括热传递，动量传递，质量传递和相变。将三维（3D）有限元数值方法应用于固态加工仿真，可以在试生产之前对金属材料的锻造过程进行分析，并获得其相关的信息，如材料流动规律，温度场和应变场。最低物理测试条件，从而预测金属材料的成形缺陷并改善其锻造质量。在总结和分析以往研究工作的基础上，阐述了金属材料固态加工的现状和意义，阐述了其发展背景，3D有限元数值模拟的现状和未来挑战，介绍了数值模拟计算的判别方法和自由表面求解方法，进行了有限元模型的几何假设，材料选择，元素划分，模型建立，参数选择以及初始和边界条件确定，并模拟和分析金属材料的流变铸造，重熔加热，触变性和旋转穿孔工艺。结果表明，三维有限元数值方法不仅可以模拟流场，温度场，应力场的各种过程，