Coupled Finite Element Simulation and Experimental Validation of Powder Compaction and Sintering

Recent advancements in finite element method (FEM)-based numerical simulations have made it possible to quantitatively analyze the compaction and sintering behavior of powder materials. However, methodologies that couple compaction and sintering processes to accurately predict the final shape and deformation behavior of sintered bodies have yet to be fully established. Moreover, such simulations require a large number of material constants and model parameters, and their appropriate identification remains a significant challenge. In this study, coupled compaction-sintering simulations were conducted for two types of powders with distinct sintering and material characteristics: yttria-stabilized zirconia (YSZ) and WC-Co. Process parameters for both compaction and sintering were determined, and the friction coefficients between the die and each powder were estimated to predict the final sintered shapes. As a result, good agreement was obtained between the simulations and experimental observations. The coupled compaction-sintering simulation developed in this study provides a practical approach for identifying friction coefficients that are otherwise difficult to measure experimentally. This methodology is expected to serve as a valuable support tool for improving dimensional accuracy and advancing process design, and thus holds significant promise for industrial applications.