Finite element modelling of bilayer iron powder compaction and evaluation on its relative density distribution using imaging technique
Multilayer compaction allows the manufacturing of advanced metal-based components ranging from long thin-walled sleeves to cutting tools. Combination of compressed powder layers has been proven to upgrade its mechanical properties in terms of its strength, durability and toughness compared to an...
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| Main Author: | |
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| Format: | Thesis |
| Language: | English |
| Published: |
2022
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| Subjects: | |
| Online Access: | http://psasir.upm.edu.my/id/eprint/99114/1/FK%202022%2073%20IR.pdf |
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| Summary: | Multilayer compaction allows the manufacturing of advanced metal-based
components ranging from long thin-walled sleeves to cutting tools. Combination
of compressed powder layers has been proven to upgrade its mechanical
properties in terms of its strength, durability and toughness compared to an
individual layer. Following this, modern apparatus has applied layering principles
to sustain the usage in daily life. Nevertheless, at the scale of research and
development, inspection on unify powder layers are scant in the aspect of its
internal density, particularly on its interconnected boundary layers or interface.
This invites untimely defects of delamination and capping that would require
unnecessary investment of time and effort during the secondary PM operation.
All the while, the scope of density measurement has resorted to geometrical
definition and hardness; thus, less modelling efforts had been undertaken to
examine the sectioned powder layers. This study has developed an imaging
technique and modelling procedures to assess the local relative density (or local
RD) distribution on green single and bilayer iron ASC 100.29 powder compact.
The modelling strategy was developed based on Finite Element Method (FEM)
using Abaqus 6.20. The results of experimental distributed local RD values
showed close agreement with values mentioned in the literature for green single
layer powder compact and the current work was further improved with higher
pixels. As expected, the modelled local RD values were validated for
experimental local RD values green bilayer iron powder compact. Further, it was
revealed that the highest local RD distribution on the interface of bilayer iron
powder compact was obtained with H/D ratio of 1.6 under lubricated die
condition. Besides, under all H/D ratios and low friction coefficient (μ of 0.08),
smaller gradient of local RD distribution has been achieved by green bilayer iron
powder compact compared to single layer iron powder compact with the same
applied conditions. |
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