Chris Nielsen is Associate Professor at the Technical University of Denmark, research affiliate and recipient of the F.W. Taylor Medal Award by the International Academy for Production Engineering (CIRP), recipient of the International KARL-KOLLE Prize for metal forming by the German Metal Forming Association. He is the co-author of two books, two book chapters, and has authored 60 papers in international journals and conferences. His research focuses on metal forming, metal forming tribology, resistance welding, and resistance sintering. Most research involves a combination of experimentation and numerical modeling. Paulo Martins is Professor of Manufacturing, at the Instituto Superior Técnico, University of Lisbon, Portugal. He is also Doctor Technices Honoris Causa of the Technical University of Denmark, and a Fellow of the International Academy for Production Engineering (CIRP). He is co‐author of six books, several international patents and over 350 papers in international journals and conferences. His main research area is manufacturing, specifically numerical and experimental-based development of forming and joining by forming processes.

• 1. Introduction2. Formability3. Finite element simulation: A user’s perspective4. Finite element flow formulation5. Introduction to the finite element solid formulation6. Tool designAppendicesA. Algebraic decomposition of the stress triaxialityB. Large elastic-plastic and rigid-plastic deformationsC. Mathematics for continuum mechanicsD. Force increment ratio that is necessary for an elastic element to yieldE. Basic cold forging processesF. Calculation of deflections and stress distributions in the die core and stress ringsG. MATLAB computer programH. Fit recommendations

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Chris Nielsen is Associate Professor at the Technical University of Denmark, research affiliate and recipient of the F.W. Taylor Medal Award by the International Academy for Production Engineering (CIRP), recipient of the International KARL-KOLLE Prize for metal forming by the German Metal Forming Association. He is the co-author of two books, two book chapters, and has authored 60 papers in international journals and conferences. His research focuses on metal forming, metal forming tribology, resistance welding, and resistance sintering. Most research involves a combination of experimentation and numerical modeling. Paulo Martins is Professor of Manufacturing, at the Instituto Superior Técnico, University of Lisbon, Portugal. He is also Doctor Technices Honoris Causa of the Technical University of Denmark, and a Fellow of the International Academy for Production Engineering (CIRP). He is co‐author of six books, several international patents and over 350 papers in international journals and conferences. His main research area is manufacturing, specifically numerical and experimental-based development of forming and joining by forming processes.

• 1. Introduction2. Formability3. Finite element simulation: A user’s perspective4. Finite element flow formulation5. Introduction to the finite element solid formulation6. Tool designAppendicesA. Algebraic decomposition of the stress triaxialityB. Large elastic-plastic and rigid-plastic deformationsC. Mathematics for continuum mechanicsD. Force increment ratio that is necessary for an elastic element to yieldE. Basic cold forging processesF. Calculation of deflections and stress distributions in the die core and stress ringsG. MATLAB computer programH. Fit recommendations

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Chris Nielsen is Associate Professor at the Technical University of Denmark, research affiliate and recipient of the F.W. Taylor Medal Award by the International Academy for Production Engineering (CIRP), recipient of the International KARL-KOLLE Prize for metal forming by the German Metal Forming Association. He is the co-author of two books, two book chapters, and has authored 60 papers in international journals and conferences. His research focuses on metal forming, metal forming tribology, resistance welding, and resistance sintering. Most research involves a combination of experimentation and numerical modeling. Paulo Martins is Professor of Manufacturing, at the Instituto Superior Técnico, University of Lisbon, Portugal. He is also Doctor Technices Honoris Causa of the Technical University of Denmark, and a Fellow of the International Academy for Production Engineering (CIRP). He is co‐author of six books, several international patents and over 350 papers in international journals and conferences. His main research area is manufacturing, specifically numerical and experimental-based development of forming and joining by forming processes.

• 1. Introduction2. Formability3. Finite element simulation: A user’s perspective4. Finite element flow formulation5. Introduction to the finite element solid formulation6. Tool designAppendicesA. Algebraic decomposition of the stress triaxialityB. Large elastic-plastic and rigid-plastic deformationsC. Mathematics for continuum mechanicsD. Force increment ratio that is necessary for an elastic element to yieldE. Basic cold forging processesF. Calculation of deflections and stress distributions in the die core and stress ringsG. MATLAB computer programH. Fit recommendations

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