Finite element analysis of rotating compression forming of powder materials.

This paper uses finite element analysis to investigate the plastic deformation and metal flow of metal powder in open-die and closed-die rotating compression forming processes. In the closed-die rotating compression forming process, the effects of forming temperature, compression pressure, rotation speed, rotation lap number, and alternating rotation frequency on the relative density and effective strain distributions inside the product are discussed. In the open-die rotating compression forming process of powder materials, the top die is controlled by speed. The effects of alternating frequency on the rotating torque, axial load, bulging ratio, and relative density are discussed. A rotating compression machine is designed and manufactured. Experiments of rotating compression forming of aluminum alloy A1050 powder material are also conducted. The hardness distributions are measured and the metallographic microstructures are observed. The measured relative density and hardness distribution are compared with the simulation results to validate the finite element modelling of rotating compression forming of aluminum powder materials. [ABSTRACT FROM AUTHOR]