Computational modelling and experimental validation of industrial forming processes by cold pressing of aluminum silicate powder

TL;DR

This paper introduces a comprehensive modelling and simulation framework for industrial ceramic powder compaction, combining continuum mechanics, finite element analysis, and optimization, validated through realistic process simulations.

Contribution

It presents a novel integrated approach for modelling ceramic powder compaction, enabling virtual prototyping in industrial ceramic forming processes.

Findings

Successful simulation of axisymmetric tablet forming

Effective parametric identification via multi-objective optimization

Validation through realistic industrial process simulations

Abstract

A novel approach to the modelling and simulation of the industrial compaction process of ceramic powders is proposed, based on a combination of: (i) continuum mechanics modelling of the constitutive response of the material; (ii) finite element discretization and computer implementation of the mechanical model; (iii) parametric identification by a multi-objective optimization of simulated experimental tests. The capabilities of the proposed approach are highlighted through computer simulations of realistic industrial compaction processes, namely, the forming of an axisymmetric tablet and of a three-dimensional ceramic tile. The presented methods and the pointed out results pave the way for the introduction of so-called virtual prototyping into the industrial practice of ceramic forming processes.