Explicit finite element method simulation of consolidation of monolithic and composite powders
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The explicit finite element method (FEM) has been used to simulate the compaction of monolithic and composite powder compacts. It is concluded that with the proper FEM model and appropriate loading speed, explicit FEM can be used to simulate powder compaction with satisfactory accuracy. The simulated pressure-density curves for four periodic powders are in reasonable agreement with experiments using model powders consisting of rods. The effects of the friction coefficient, Poisson’s ratio, and hardening exponent on densification are investigated. Powder compacts consisting of particles with larger Poisson’s ratio, larger interparticle friction, and larger hardening exponent are more diffcult to consolidate in monotonic compaction. Compaction of multiparticle arrays is also simulated to assess the effects of packing randomness and particle rearrangement. The results reveal that local packing details affect the compaction behavior and, in general, the more heterogeneous the powder mixture is, the more difficult it is to consolidate the powder compact. Networking of hard particles significantly increases the densification resistance.
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