Abstract: A new algorithm of hexahedral mesh automatic generation and regeneration, surface layer method, is presented, which includes identification of CAD or remeshing model, generation of core mesh, boundary mesh fitting, surface element layer (SEL) generation and mesh smoothing technology. The research results clearly indicate that the algorithms proposed in this study is simple in principle, robustness in programming and can generate high-quality hexahedral mesh. It is an ideal automatic generation and regeneration algorithm of hexahedral mesh for the finite element simulation of three-dimensional material forming processes.

Key words: Finite element simulation, Hexahedral mesh, Material forming process, Surface element layer