Real-Time Design of Improved Powder Pressing Dies Using Finite Element Method Modeling

A predictive model for powder compaction has been developed that incorporates unprecedented flexibility to design powder press tooling and reliable powder pressing processes. Sandia’s finite element (FE) toolkit comprises the heart of the modeling software, and a unique concept was developed to design a variable dimension and parameter template to easily build/design dies/components on a computer. The result is user-friendly software to simulate powder compaction that can run on a desktop or laptop personal computer by a non-expert with minimal training. The software has been tested and validated by direct comparison to experimentally measured density gradients in green ceramic powder compacts. The software has been used successfully to enhance our fundamental understanding of ceramic powder pressing, and has provided guidance to achieve better process reproducibility, reliability, and control. This technology will contribute significantly to press powder manufacturing by: 1) reducing manufacturing costs, cycle time, and waste; 2) enabling more cost effective manufacturing of specialty components and small lot sizes; 3) reducing tooling and component design, development, and prototype time; and 4) maximizing design and manufacturing flexibility/agility.