Finite Element Analysis of the Compaction Processes for Hollow Three-Level (Class IV) Components

Abstract

The yield criterion describing asymmetric behavior of powdered metal compacts in tension and compression is introduced by modifying that used for sintered powdered metals. The plasticity theory related to the modified yield criterion is reviewed and summarized for a powdered metal compact. The constitutive equation is applied to the variational principle and its discritization is also introduced. Axisymmetric die pressings with copper powders were performed to see the deformation mechanics of hollow three-level parts. The simulation includes two different types of multiple-motion tooling compaction of a Class IV part of hollow three-level component. Predictions are made for density distributions, load-stroke relationships, average density as function of height, pressure distributions along the die-walls and punches, average compact densities at each level, and energy consumption for each pressing. The information from simulation can be used to synthesize the various punch motions in a multiple action tooling system.