Numerical simulation of ductile metal powder compaction using advanced distinct element method

Metal powder compaction is widely employed in industries to manufacture parts such as gears, bearings, and soft magnetic composites (SMCs). The advanced distinct element method (ADEM), which can simulate plastic deformation and any particle shape, is promising for simulating metal powders that have broad-range characteristics, such as ductile or brittle powders with isotropic or anisotropic shapes. In this study, experimental compaction tests and simulations were conducted on spherical (i.e., isotropic) and flake-like (i.e., anisotropic) ductile pure-iron powders to confirm the validity of using the ADEM to simulate metal powder compaction. Single-particle compression tests were also conducted to identify the simulation parameter affecting the elastic and plastic behaviors of the powders. In the case of spherical-powder compaction simulation, the stress–strain curve determined by particle movement and deformation behavior was found to be consistent with the experimental results. Thus, the ADEM adequately simulates not only particle deformation but also the frictional force between particles and the die wall, which play an important role in powder compaction. Further, in the simulation of the flake-like powder, the ADEM again reproduced key experimental results well.