Contact friction simulation in powder compaction process based on the penalty approach

In this paper, the influence of powder–tool friction on the mechanical properties of the final product is investigated in pressing metal powders. A computational algorithm is presented for simulation of frictional contact in the compaction process of powder. The large deformation finite element (FE) formulation is characterized by the use of penalty approach in which a plasticity theory of friction is incorporated to simulate sliding resistance at the powder–tool interface. The constitutive relations for friction are derived from a Coulomb friction law. A double-surface cap plasticity model is employed together with the nonlinear contact friction behavior in numerical simulation of powder material. The contact friction algorithm together with the cap plasticity model is incorporated within the framework of large FE deformation in order to predict the non-uniform relative density distribution during large deformation of powder die pressing. Finally, the numerical schemes are examined for efficiency in modeling of a set of powder components.