Simulation of ceramic tile sintering using a modified SOVS model under industrial production conditions

This study presents an enhanced Skorohod–Olevsky Viscous Sintering (SOVS) model for porcelain stoneware tiles, incorporating the effects of microstructural evolution and a semi-empirical formulation for temperature-dependent viscosity. The model is implemented using open-source tools (CodeAster and MFront) within a Finite Element Method (FEM) framework to simulate shrinkage and density evolution during firing, including the influence of pressing-induced defects. The proposed formulation is validated through a combination of laboratory-scale tests (dilatometric and thermogravimetric analyses) and full-scale industrial trials (hydraulic press and industrial kiln). Non-destructive techniques (X-ray absorption and coordinate-measuring machine) were used to assess thickness and density distribution maps, as well as dimensional stability. The results demonstrate excellent agreement between model predictions and experimental measurements, confirming the robustness of the model to accurately reproduce densification, shrinkage and geometrical distortions in a manufacturing environment.