State of the art review - Comparison of computer models representing powder compaction process

This paper presents a benchmark study on the use of simulation models to re present the powder compaction process. A two level part that represents a s ynchroniser hub is used as detailed experimental information for this part is documented in the literature. The models used incorporate different repr esentations of friction and material yielding behaviour together with diffe rent fill densities. The study shows that computer modelling is capable of predicting density distributions and tool set force levels for the powder c ompaction process. It has highlighted the sensitivity of the output with re spect to friction, fill density, and material yield models. It has also sho wn that models that incorporate material behaviour using different material models yield surprisingly reasonable results. Based on best performance, i t is now possible to predict density to within 0.05 g cm(-3) and tool set f orce within 10% for an iron powder. The computational requirements indicate a simulation time of typically 1 h for a two level component. This makes s imulation a practical tool for this industry sector. PM/850.