Dynamic modeling of powder compaction processes via a simple contact algorithm

In this paper, the dynamic modeling of powder compaction processes is presented based on a simple contact algorithm to evaluate the distribution of final density in dynamic powder die-pressing. The large deformation frictional contact is employed by imposing the contact constraints via the contact node-to-surface formulation and modifying the contact properties of frictional slip. The Coulomb friction law is used to simulate the friction between the rigid punch and the work-piece. The nonlinear contact friction algorithm is employed together with a double-surface cap plasticity model within the framework of large FE deformation in order to predict the non-uniform relative density distribution during the dynamic simulation of powder die-pressing. Finally, the numerical schemes are examined for accuracy and efficiency in modeling of a set of powder components.

► The dynamic FE simulation is performed for powder compaction processes. ► A simple contact algorithm is presented for dynamic powder die-pressing. ► The large deformation frictional contact is employed in the compaction process. ► A double-surface cap plasticity model is appled into the large FE deformation. ► The relative density distribution is obtained in dynamic powder die-pressing.