1M. Sc. [Engg.] Student, Department of Mechanical and Manufacturing Engineering, M. S. Ramaiah School of Advanced Studies, Bangalore, 560 058
2Professor and Head, Department of Mechanical and Manufacturing Engineering, M. S. Ramaiah School of Advanced Studies, Bangalore, 560 058
Online published on 18 February, 2020.
Many advantages are inherent to successful powder metallurgy (P/M) process especially in high volume manufacturing. The process consists of a compaction stage (produces low strength green part) and a sintering stage (bonds particles together thereby increases parts strength). The strength/density distribution of the compacted product is crucial to overall success. The finite element analysis (FEA) has become an effective way to numerically simulate strength/density distribution in a P/M compact.
The objective of the study was to simulate compaction process to achieve uniform and high bulk density green parts. A material model (Cam-Clay) which can capture the particle re-arrangement under compaction process has been adopted. An axi-symmetric analysis has been followed on 601AB aluminium alloy powder with initial apparent density as 40%.
A finite element model with upper and lower punch displacement control was formulated and solved in ABAQUS. The study revealed that, 55 to 56% (in this case 14mm) of the punch displacements can result in 100% relative density at upper and lower corners. It was observed that maintaining friction coefficient 0.15 to 0.2 would produce better density distribution in the powder compact. H/D ratio recommended for obtaining higher and uniform relative density for 56% compaction is 2–3. Higher H/D will result in large variation in relative density distribution whereas lower H/D result in less than 100% density in any portion of the compact.
Powder Compaction, 601AB Aluminum Powder
