Powder Compaction

Design & simulation solutions for Powder Compaction.

Engineers designing for powder compaction face challenges related to material variability, complex compaction mechanics, and the need for robust die design to ensure consistent density and strength in the final product. Precise control of processing parameters and effective management of post-compaction treatments are crucial for achieving high-quality outcomes. Additionally, environmental factors and energy efficiency must be considered to develop effective and sustainable compaction techniques.

Ensuring Uniformity and Density

Uneven particle distribution leads to density gradients, weak zones and cracks in the compacted material. It is difficult to predict how powder properties such as size, shape and cohesion affect filling and pressing behaviour, leading to a trial and error based approach. This in turn leads to poor uniformity, reduced strength and low quality while increasing scrap rates.

Rocky DEM can simulate the particle filling process in 3D, taking into account particle motion, compression, rearrangement and local density changes, allowing engineers to assess stress distrubution of the final product whilst making informed decisions about material properties and filling characteristics. This leads to improved density profiles, high product strength and performance, reduced production failures and optimised die and feeder design for reduced design iterations and waste.

Optimising Tooling and Compaction Speed

There are complex interactions between the press speed, punch geometry and powder flow which can cause internal defects like lamination, capping or voids. Engineers relying on empirical data to design their systems struggle to get good correlation between data and full scale implementation, making the design of new or complex shapes challenging. Physical testing can be used to mitigate some of this risk, but it is time consuming and expensive, especially if considering a multi stage system. End results without simulation include low quality parts, machine wear and tooling failure, which increases downtime and reduces output.

Rocky can accurately simulate the entire dynamic compaction process, through punch movement, powder rearrangement and consolidation. Press speed, force and sequence can all be tested and optimised to ensure optimal material properties, while eliminating voids, air entrapment and particle slippage. This leads to higher product quality, optimised systems to ensure production speed without failures, and enables robust data to drive tooling decisions.

Predicting Wear, Sticking and Flow

Sticky or cohesive powder can cause inconsistent fills as well as material build up that requires frequent cleaning and operator intervention. Material variations are hard to design for and testing under realistic conditions is difficult. This leads to reduced throughput, increased operator workload and part defects.

Rocky can tackle the simulation of non-spherical particles, cohesive forces and wall interactions with ease. It allows engineers to simulate hopper discharge, die fill and particle wall sticking, as well as allowing the testing of different wall materials, surface finishes or vibration assist strategies. Simulation with Rocky also provides insight into wear prediction to allow cleaning and maintenance to be optimised. This combines to provide a reliable solution with consistent die filling, less material sticking and improved throughput.

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