Numerical Simulation and Experimentation of Warm Metal Powder Compaction Process

Abstract

Powder compaction at elevated temperature or known as warm compaction is a process of producing green compacts from metal powder, which is generally conducted between the ambient and the recrystalization temperature of the main powder constituent. Even though, warm compaction was initiated at around 1998, not a lot of information can be found in the literature especially on the numerical simulation of the process. Therefore, this paper presents the simulation of warm metal powder forming process by using the developed computer code. The Elliptical Cap yield model has been used to represent the deformation behaviour of the powder mass during the forming process at above ambient temperature. The material properties of powder mass, i. e., friction coefficient, elastic index, and plastic index, at different forming temperature, are established through warm compaction experiment. The simulation was conducted to generate a green compact of a plain bush component. Some numerical simulation results were validated through experimentation, where a good agreement was found between the numerical simulation and the experimental results.

The Effects of Sintering Schedule to the Final Properties of Iron Powder Compacts Formed through Warm Compaction Route

“…5). At higher sintering temperature, i.e., 1000ºC, the bonding among iron particles are occurred properly hence the bonding strength became higher [19]. Therefore, components sintered at higher temperature have higher strength.…”

Effect of Feedstock Preparation and Forming Temperature to the Characteristics of Green Compacts

“…It has generally been accepted that green compact generation through powder compaction process is dependent on feedstock preparation and forming temperature [9][10][11][12][13][14][15]. Feedstock preparation refers to the mixing of metal powder with a certain amount (wt%) of lubricant (and additives) for a certain duration of time in order to produce a homogeneous powder mass prepared for forming.…”

Stamping coal cake simulation with Duncan–Kelvin–Maxwell constitutive relations

“…Hence, the well established FEM was adopted. In addition, in the research work on dynamic compaction 10,11 and powder compaction, 12,13 which bear some resemblances to stamping coal cake, FEM has been successfully applied. In these problems, as a key issue, the constitutive model of the compacted material is usually considered as a linear relation combined with Mohr–Column strength criterion, which provides neither the non-linearity nor the strain accumulation, leading to an unreasonable simulation result.…”