A three-dimensional finite element analysis of a powder compaction process was undertaken to determine the optimum manufacturing conditions for the complex cylinder block found in the hydraulic pump of an excavator. A porous material model was used to ascertain the material behaviour. The finite element predictions for both the density distribution and compaction load were in good agreement with experimental results.

In this paper, three-dimensional finite element analysis of thread rolling process of a 12 point flange head bolt is conducted using a rigid-plastic finite element method based metal forming simulator AFDEX 3D. A whole sequence of cold forming processes of a long shaft bolt composed of four forging stages and final thread rolling process is simulated to reveal the mechanism of thread formation. A mesh density control function is applied near the major plastic deformation region to achieve computational efficiency. It has been shown both numerically and experimentally that longitudinal lengthening or shortening is negligible in thread rolling.