Finite Element Modeling on the Compaction of Copper Powder Under Different Conditions

Single-action die compaction of copper powders with initial loose natural packing and vibrated random dense packing structures was carried out numerically by finite element method and physically for validation. Furthermore, the compaction under various cyclic loadings was modeled to identify its effects on the compact properties. The results were analyzed and compared between compacts formed at different initial packing structures and different forming conditions, which indicate that at the same pressure, single-action die compaction on the dense uniform initial packing can produce compacts with high relative density, uniform density and stress distributions, which implies the necessity to improve initial packing density and uniformity in forming high performance compacts. Meanwhile, by using cyclic loading on such dense initial packing structures, compacts with higher packing density and more uniform density and stress distributions can be created. The numerical and physical results are comparable and in good agreement with the proposed double logarithmic equation.