Abstract
Working conditions in mushy-state plane-strain upsetting of rectangular magnets contained in steel capsules with concave or convex dies are determined by numerical simulation using the distinct element method. The motion of the grains in the mushy state rare-earth magnet is calculated by the distinct element method and the plastic deformation of the capsule containing the magnet is calculated by the viscoplastic finite element method. In addition, a model experiment using acrylic resin grains, a Vaseline liquid phase and a plasticine capsule is carried out. The aspect ratio of the magnet, the volume ratio of the capsule and the die angle are chosen as the working conditions, and the degree of grain alignment and the crop loss for formed magnets are evaluated. Although the effect of the aspect ratio of the magnet is large, those of the volume ratio of the capsule and the die angle are comparatively small.
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