Computational modeling of 3D powder compaction processes

In this paper, the 3D numerical simulation of powder compaction processes is presented using a double-surface plasticity theory. A cone-cap plasticity model based on a combination of a convex yield surface consisting of a failure envelope and a hardening cap is developed for nonlinear behavior of powder materials in the concept of the generalized plasticity formulation. The constitutive elasto-plastic matrix and its components are derived based on the definition of yield surface, hardening parameter and nonlinear elastic behavior, as function of relative density of powder. A computational algorithm is presented from the viewpoint of efficient numerical modeling for the double-surface plasticity. The numerical simulation is illustrated in the modeling of 3D rotational-flanged, connecting-rod and shaped seal-disk components. (c) 2006 Elsevier B.V. All rights reserved.