An improved material point method for coining simulation

Abstract

Extremely small time step caused by large deformation in coining process significantly increases computational time in dynamic explicit finite element method (FEM). Furthermore, negative volumes of distortion elements in the rim of coin lead to abnormal termination of simulation. In order to overcome these problems, dynamic explicit material point method (MPM) is employed for coining process. However, most of the point-to-point contact algorithms in MPM cause fake contacting detection. In addition, abundant tiny patterns on die surfaces put forward high requirement for the contact algorithm to calculate the normal vectors. A point-to-segment based contact algorithm is proposed to obtain accurate normal vectors at real physical contact point and embedded into the framework of modified update stress last (MUSL) for simulating coining. Amount of data storage and computations are reduced since the background domain only contains the deformable workpiece and one velocity field is required. The improved MPM is applied to predict insufficient filling during minting, and its performance is validated by experimental results.