Finite Element Simulation of the Cold Open-Die Forging of Sintered Aluminum Metal Powder Trapezoidal Preforms

Abstract

This paper presents finite element simulation of the forging of sintered aluminium metal powder trapezoidal preforms at cold conditions. It involves basic experimental investigations followed by the finite element simulation of the forging process under consideration by the use of DEFORM. The basic experimental work includes the fabrication of compaction die-sets, production of aluminum metal powder trapezoidal preforms and simple compression test to obtain load-deformation data. The stress-strain data was added to the software material library and appropriate composite interfacial friction law including both sliding and sticking frictions along with appropriate compatibility conditions were modeled. The entire forging process was simulated into 20 stepped die stroke movement, consisting equal steps of 0.22 mm. The distribution of effective stress, effective strain, effective strain-rate, total energy dissipation, average die load and flow velocity were obtained and critically investigated. It is expected that the present work will be useful for the assessment of various deformation characteristics during mechanical processing of sintered materials.

Keywords: Finite element simulation, trapezoidal preforms, sintered, open-die, forging process.