Numerical simulation of residual stress field in green power metallurgy compacts by modified Drucker–Prager Cap model

Abstract Compaction process simulation and residual stress prediction of green PM compact were carried out with elasto-plastic 3D FEA based on the modified Drucker–Prager Cap model in Abaqus. The model parameters of the investigated powder Distaloy AE were determined as functions of relative density through typical mechanical property tests of powder. The model was implemented as a user subroutine USDFLD. Single sided compaction of a d 20 mm×5 mm disk green compact of Distaloy AE was simulated, and the residual stress of the disk after ejection was predicted with FEA. The FEA results of the compaction process and the residual stress of the disk show good agreement with compaction experiments and X-ray diffraction measurements, which validates the model and its parameters. The results indicate that the compressive residual stresses exist mainly in a thin layer on the side surface, but the residual stresses are very small on the top and bottom surfaces.