Adaptive finite element remeshing in a large deformation analysis of metal powder forming

In this paper, a general framework for the finite element simulation of powder forming processes is presented. A large displacement formulation, based on a total and updated Lagrangian formulation and an adaptive finite element strategy based on error estimates and automatic remeshing techniques are utilized. To describe the constitutive model of the highly non-linear behaviour of powder materials, an elliptical cap model based on a hardening rule to define the dependence of the yield surface on the degree of plastic straining is applied. The interfacial behaviour between the die and powder is modelled by using a plasticity theory of friction in the context of an interface element formulation. Finally, the powder behaviour during the compaction of a set of complex shapes are analysed numerically. The simulation of the deformation is shown as well as the distribution of relative density contours at different time stages. The results clearly indicate that the algorithm makes it possible to simulate the powder forming problems efficiently and automatically. Copyright (C) 1999 John Wiley & Sons, Ltd.