Finite element simulation for dynamic large elastoplastic deformation in metal powder forming

In this paper, a transient dynamic analysis of the powder compaction process is simulated by a large displacement finite element method based on a total and updated Lagrangian formulation. A combination of the Mohr–Coulomb and elliptical yield cap model, which reflects the stress state and degree of densification, is applied to describe the constitutive model of powder materials. A Coulomb friction law and a plasticity theory of friction in the context of an interface element formulation are employed in the constitutive modelling of the frictional behaviour between the die and powder. Finally, the powder behaviour during the compaction of a plain bush, a rotational flanged and a shaped tip component are analysed numerically. It is shown that the updated Lagrangian formulation, using a combination of the Mohr–Coulomb and elliptical cap model, can be effective in simulating metal powder compaction.