Abstract
This paper presents a benchmark study on the use of simulation models to represent the powder compaction process. A two level part that represents a synchroniser hub is used as detailed experimental information for this part is documented in the literature. The models used incorporate different representations of friction and material yielding behaviour together with different fill densities. The study shows that computer modelling is capable of predicting density distributions and tool set force levels for the powder compaction process. It has highlighted the sensitivity of the output with respect to friction, fill density, and material yield models. It has also shown that models that incorporate material behaviour using different material models yield surprisingly reasonable results. Based on best performance, it is now possible to predict density to within 0·05 g cm-3 and tool set force within 10%for an iron powder. The computational requirements indicate a simulation time of typically 1 h for a two level component. This makes simulation a practical tool for this industry sector.
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