Analysis of Powder Compression Molding for

Automotive Components Using Finite Element Method

Bum Suk Oh1, Ju Gwang Jang2, Key Sun Kim3*

1 Div, of Mechanical & Automotive Engineering, Kongju National University, 331717

Cheoan, Korea 2 Div, of Mechanical & Automotive Engineering of Kongju National University, 331717

Cheoan, Korea 3* Div, of Mechanical & Automotive Engineering, Kongju National University, 331717

Cheoan, Korea

keysun@kongju.ac.kr

Abstract. The present study was conducted concerning powder compression

molding of automotive components, with the purpose of obtaining optimum

conditions through numerical simulation of changes in relative density

distribution produced upon powder compression as a function of change in

friction forces between the mold and the material by using FEM. By varying

friction coefficients, 4 cases of the variable were considered, and a total of 2

stages of compression process were implemented starting with the initial

density. As a result, a uniform relative density distribution could be observed

when the coefficient of friction was (c).

Keywords: Sintering, Density distribution, Powder Metallurgy.

1 Introduction

In general, powder metallurgy method is one of the widely employed methods as a

manufacturing technique for contemporary metal and ceramic products, and involves

pressure molding of powder, followed by sintering at high temperatures to obtain final

products.[1] Advantages of the powder metallurgy method include reduction in

processing unit cost by omission of machining processes and ability to mix diversified

materials. However, the method has a disadvantage of being difficult to obtain

uniform density distribution in the product due to the process characteristics. When

deviations in density distribution are large, distortion occurs upon sintering.[2]

Since obtaining uniform density in powder compression process is an important

item to remove distortion which can occur during sintering process, it is an item

which must always be considered. Thus, numerical simulation for distribution of

strength or density in powder compression process by using FEM(Finite Element

Method) can be an effective method.[3,4]

3* Key Sun Kim is the corresponding author

Advanced Science and Technology Letters Vol.140 (GST 2016), pp.207-210

http://dx.doi.org/10.14257/astl.2016.140.40

ISSN: 2287-1233 ASTL Copyright © 2016 SERSC

In the present study, distortion characteristics in the density disribution as a

function of friction coefficients was considered to obtain uniform density distribution

for automotive components. To quantitatively analyze the effects of friction

coeffecient between the mold and the material on distortion characteristics of density

distribution, analysis by FEM has been utilized, which was implemented in 3-

dimension by using a commercial dedicated software of DEFORM-3D.[5,6]

2 Method

2.1 Modeling and Materials

Fig.1 shows modeling for upper punch, lower punch, mold die, and automotive

component. Material used in the present study is 0.08%C carbon steel, chemical

composition data of which is given in Table 1. And the mechanical properties

summarized in Table 2.

Fig. 1. Modeling

Table. 1. Chemical composition of the metal powder

C (%) Si (%) Mn (%) P (%) S (%)

0.08 0~0.1 0.5~0.8 0~0.04 0.08~0.13

Table. 2. Mechanical properties of the material

Ultimate Tensile

Strength

Yield Tensile

Strength

Elongation

(in 50mm)

Young’s

Modulus Poisson’s Ratio

385MPa 325MPa 20% 205GPa 0.29

Advanced Science and Technology Letters Vol.140 (GST 2016)

208 Copyright © 2016 SERSC

2.2 Boundary Condition and Analysis Method

In the present study, meshing for FEM involved division into tetrahedron meshes.

And friction coefficients between the mold and the powder material were varied for a

total of 4 cases to conduct the analysis.

Compression process proceeded in 2 steps starting from the initial density of the

material. In the 1st step, Upper Punch applied pressure in –Z direction. In the 2nd step,

Lower Punch applied pressure in +Z direction, and compression molding analysis was

conducted. Process steps of the material are shown in Fig.2.

Fig. 2. Mesh and Manufacturing process

3 Analysis Result

In the present analysis, friction coefficients were varied and compression molding

analysis was coducted with application of pressure to the initial density by Upper

Punch and Lower Punch, respectively, and the density distribution graph for the final

molding analysis results and the final shape are shown in Fig.3.

Density distribution for the component surface is shown in Fig.3, and it can be seen

that a constant degree of relative density distribution is exhibited for the coefficient of

friction of (c).

Fig. 3. Density distribution of changes in Friction coefficient

Advanced Science and Technology Letters Vol.140 (GST 2016)

Copyright © 2016 SERSC 209

4 Conclusion

In the present study, density distribution in the product upon compression molding of

an automotive component was considered as a function of friction coefficients, and

the following results could be obtained.

1. For the coefficient of friction of (c) between the mold and the material, a uniform

relative densidity distribution was observed. Based on which a conclusion could

be drawn that the most uniform density distribution occurred for the coefficient

of friction of (c).

2. For commercialization of powder compression products with uniform density

distribution, additional studies on the effects of change in friction forces

depending on lubricant on frictional behavior are expected necessary in the future.

Acknowledgements. This work was supported by the research grant of the Kongju National

University in 2016.

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