Finite Element Simulation of the Compaction and Springback of Alumix 321 PM Alloy

Stanley G Selig,Darrel A Doman

doi:10.1155/2015/283843

Abstract

A finite element simulation of the compaction and springback of an aluminum-based powder metallurgy alloy (Alumix 321) was developed and validated using the LS-DYNA hydrocode. The present work aims to directly address the current scarcity of modeling works on this popular alloy system. The Alumix 321 constitutive material parameters are presented. The model can predict the results of single-action compaction as well as the amount of springback experienced by a compact upon ejection from the die. The model has been validated using a series of experiments including powder compaction, optical densitometry, and the creation of a compaction curve.

Highlights

Powder compaction is a critical step in the powder metallurgy (PM) process since the overall performance of a PM part is largely based on the quality of the compaction
It is for these reasons that this work investigates the density distribution and springback found within PM parts
FE model Experimental conducted to attempt to match the bulk density of the finite element sample at each compaction pressure to the experimental samples

Summary

Introduction

Powder compaction is a critical step in the powder metallurgy (PM) process since the overall performance of a PM part is largely based on the quality of the compaction. Strength and other material properties increase with density, so it is important that the part is both dense and uniform after the compaction step. As strength and other material properties increase with density, the reliability of PM parts is affected by both the bulk density and density gradients within the green compacts. The dimensional tolerance of the final compact is affected by warping during sintering as well as the elastic springback experienced by the green compact upon ejection from the die [1]. It is for these reasons that this work investigates the density distribution and springback found within PM parts. Due to its attractive engineering qualities Al PM research is expanding, with recent works focusing on as-made mechanical properties [2] and sintering responses [3]

Methods

Results

Conclusion