The article analyzes the stress-strain state in the zone of plastic deformation during special caliber rolling. The principle of caliber rolling technology is described, which makes it possible to combine shear and compression deformations in the cross-section of metals, alloys, and metal-matrix composites. The analysis results of stresses and strains during shear rolling in a diamond pass, which included compressive strains that had not been considered in previous studies, revealed that localization or point inversion of stresses and strains is observed in the plastic deformation zone. Stress and strain are localized along the minor and major diagonals of the diamond pass.

The plastic deformation behaviour of 7075 aluminium alloy during the forging process was studied using Deform 3D software. The simulation process was carried out at a constant die velocity of 5 mm/s and a varying forging temperature between 250°C and 400°C. The results showed that the forging load increased with a decrease in the forging temperature. The effective strain rate, strain and stress distribution were inhomogeneous across the deformed workpiece, indicating nonuniform forging process. It was observed that the reduction in the forging temperature during the process was responsible for the inhomogeneity. The flow curves obtained using finite element simulation code are consistent with experimental results reported in literature.

In the present research work using a backward cup extrusion (BCE) die profile, different lubricating conditions on aluminum alloy AA6063 have been experimentally and numerically investigated to predict the extrusion load. It was obvious that due to an increase in applications of the extrusion process, many researchers have worked on the extrusion process using different methods to achieve their aims. This experiment was conducted with three different lubricants namely: Castor oil, Palm Oil and tropical coconut oil; as well as without lubricants. Different lubricating conditions were employed of varying strain rates ranges from 1.5×10-3s-1, 2.0×10-3s-1, 2.5×10-3s-1, and 3.0×10-3s-1; Numerical analysis and simulation for dry and lubricated conditions during extrusion load were also performed using DEFORM 3D software. The results show that prediction extrusion load increases with increasing strain rates. The maximum extrusion load was found to be higher for extrusion without lubricants. In all cases of strain rate, palm oil showed a lower extrusion load compared to the other lubricants. Castor oil indicated the highest extrusion load when the experiment is carried out using lubrication. There was a consistent agreement between the result gotten from the experiment and simulation result of the extrusion load-strike curve.

A Deform^TM-3D analysis was used to illustrate the effect of strain rate on isothermal deformation (forging) of X20CrMoV121 steel. The simulation process was conducted at an isothermal temperature of 850 °C and varying the strain rates of 1.9 s^-1, 2 s^-1 and 3 s^-1. The results of temperature, strain and stress distribution at various strain rates were reported. The strain/stress distribution exhibited a heterogeneous distribution, indicating inhomogeneity during hot forging. It was also shown that the deformation inhomogeneity decreased with the increase in the strain rate. The results are comparable to experimental publications, indicating that Deform^TM-3D is an effective tool for finite element analysis of hot deformation processes.