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Abstract: An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted FE elements to EFG domain in analysis. A new scheme to implement adaptive conversion and coupling is presented. The coupling method takes both advantages of finite element method (FEM) and meshless methods. It is capable of handling large deformations with no need of remeshing procedures, while it is computationally more efficient than those full meshless methods. The effectiveness of the proposed method is demonstrated with the numerical simulations of the bulk metal forming processes including forging and extrusion.

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