3D dynamic modeling of powder forming processes via a simple and efficient node-to-surface contact algorithm

In this paper, a simple and efficient contact algorithm is presented for the evaluation of density distribution in three-dimensional dynamic modeling of powder compaction processes. The contact node-to-surface algorithm is employed to impose the contact constraints in large deformation frictional contact, and the contact frictional slip is modified by the Coulomb friction law to simulate the frictional behavior between the rigid punch and the work-piece. The 3D nonlinear contact friction algorithm is employed together with a double-surface cap plasticity model within the framework of large finite element deformation in order to predict the non-uniform relative density distribution during the dynamic simulation of powder die-pressing. The accuracy and robustness of contact algorithm is verified by the impact analysis of two elastic rods, which is compared with the analytical solution. Finally, the performance of computational schemes is illustrated in dynamic modeling of a set of powder components.