A new computational algorithm for 3D contact modeling of large plastic deformation in powder forming processes

In this paper, the three-dimensional large deformation frictional contact of powder forming process is modeled using a simple computational algorithm based on the augmented-Lagrange approach. The technique is applied by imposing the contact constraints and modifying the contact properties of frictional slip through the node-to-surface (NTS) contact algorithm. The Coulomb friction law is employed to simulate the friction between the rigid punch and the work-piece by the use of penalty and augmented-Lagrange approaches. It is shown that the augmented-Lagrange technique significantly improves imposing of the constraints on contact surfaces. The nonlinear contact friction algorithm is employed together with a double-surface cap plasticity model for highly nonlinear behavior of powder within the framework of large FE deformation in order to predict the non-uniform relative density and stress distributions during the large deformation of powder die-pressing. Finally, the numerical schemes are examined for accuracy and efficiency in modeling of a set of powder components.