Optimizing powder compaction for enhanced relative density: Insights from multi-particle finite element simulations and genetic algorithm

Abstract

Abstract. In this study, multi-particle finite element simulations in powder compaction were performed to analyze the effects of the size of the representative volume element (RVE), the number of elements per particle, and particle size distribution. Simulation parameters were calibrated to accurately predict the relative density of compacts derived from two types of powders. The influence of RVE size across four mixtures was examined to obtain its relationship with relative density. The impacts of particle size distribution and element number per particle were studied. The results indicate a decline in relative density with increased element size. Moreover, a genetic algorithm is employed to determine the optimum mixture composition yielding the highest relative density at 1400 MPa.