Numerical modeling of cold powder compaction using multi particle and continuum media approaches

• The effect of modeling approach and material models was studied for powder compaction process.
• Multi-particle approach along with von Mises yield function yielded more realistic results.
• Mohr–Coulomb, and Shima–Oyane models in continuum approach yielded more realiable results.
• Increasing friction led to increasing deformation and harsher contact interactions.

Numerical analysis of powder compaction process requires multi-particle modeling approach as continuum models fail to simulate the nature of process (e.g. interparticle, and particle–die interactions), accurately. This study aimed for analyzing powder compaction process utilizing 3-D finite element modeling approach along with different material models including modified Cam-Clay, Mohr–Coulomb, Shima–Oyane and von-Mises. The finite element analyses were carried out by implementing multi-particle finite element method. Moreover, continuum modeling was also performed for comparison purposes. In both cases, the compaction of spherical copper particles was analyzed at room temperature conditions. The obtained FEA results were compared in terms of equivalent stress and strain, and deformed shape. Results showed that the FE models in which von-Mises and modified Cam-clay material models were used yielded results of similar magnitude while those of Shima–Oyane and Mohr–Coulomb material models resulted in equivalent stress and strain values are in close proximity. Effect of coefficient of friction on the results was also investigated by implementing three distinct coefficients of friction (μ = 0.1, 0.25, 0.4). It was noted that increasing friction resulted in elevated level of deformation for the particles and harsher particle–particle, and particle–die contact interactions.

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