Powder compaction modelling via the discrete and finite element method

A discrete and continuum modelling approach to powder compaction is presented and discussed. The work demonstrates the ability of the discrete method to capture the compression of a ductile matrix and a matrix comprising a ductile and brittle assembly. The discrete element analysis is compared with a Gurson model for the compression of a ductile porous system with reasonable agreement. A continuum model is demonstrated by comparison with results from an experimental study and other numerical investigations. For a steel powder, this displays agreement in predicted density within 0.23 g/cm3 and upper punch force level within 16%. These levels of agreement are encouraging and are within the requirements to be useful for industrial application. Similar good agreement is also demonstrated when compared with a simulation of the pressing of a ceramic tip which features extreme changes in density throughout the compact.