Abstract
This paper presents a validated co-simulation framework for bidirectional coupling between continuum material behaviour, modelled with the Finite Element Method (FEM), and rigid-body dynamics and control, modelled with Multi-Body Dynamics (MBD), exemplified for metal powder compaction in a hydraulic press. The framework addresses how evolving material non-linearity (strain-dependent stiffness during densification) couples to actuator dynamics and closed-loop control in an industrial setting. A strain-dependent FEM model implemented in open-source Code_Aster is integrated with an MBD model of a fixed-die hydraulic press including servo-valve flow, pressure dynamics, viscous-Coulomb friction, and a PID controller with velocity feed-forward. Force and displacement are exchanged at every simulation step so that FEM reaction forces drive hydraulic dynamics, and MBD displacements become FEM boundary conditions. Validation against high-frequency press sensor data (positions, pressures, forces) shows position errors below 0.1% in closed-loop operation and moderate force deviations, while open-loop simulations reproduce classical densification patterns from the literature. A key engineering result is that early pressure build-up via feedback control reduces radial density gradients and removes low-modulus regions compared to open-loop operation. The validated, open-source framework therefore provides an engineering tool for studying and improving powder press trajectories, density uniformity, and hydraulic system performance in industrial applications.