Finite Element Simulation and Experimental Validation for Multilevel Powder Compact

Abstract

The simulation of a complete cold compaction cycle for a green powder component and an experimental comparison are presented. In the modelling development, the powder was assumed to be a rate independent elastoplastic material. The process was described by a small displacement based finite element formulation and an elliptical cap yield surface was used to represent the powder densification. A friction model based on a plasticity analogy was found to be necessary in the analysis of the part ejection process. Laboratory and factory based experiments were carried out to provide detailed information about the material parameters, tooling motion, and validation of the numerical simulation work. Two examples were studied, a plain bush component and an axisymmetric flanged component. The numerical simulation results were validated against the experimental data and the comparison showed good agreement. The versatility of the simulation allows the complete representation of the green compact generation cycle. PM/0776