Numerical Analysis of Compressive Flow and Fracture Toughness of Aluminum Powder Compacts

Mohammed Y. Abdellah^{1, 2,} , Nadia E. Bondok^{3, 4} and Hamza A. Ghulman²

¹Mechanical Engineering Department, Faculty of Engineering, South Valley University, Qena

²Mechanical Engineering Department, Collage of Engineering and Islamic Architecture, Umm Al-QuraUniversity Makkah, KSA

³Department of technology Development, Specified Studies Academy, Worker’s University, Cairo, Egypt

⁴Interior Design Department, Faculty of Design and Architecture, Jizan University, Saudi Arabia

Cite this paper:
Mohammed Y. Abdellah, Nadia E. Bondok and Hamza A. Ghulman. Numerical Analysis of Compressive Flow and Fracture Toughness of Aluminum Powder Compacts. American Journal of Materials Engineering and Technology. 2016; 4(2):16-21. doi: 10.12691/materials-4-2-1

Abstract

The finite element analysis (FEA) has become an effective way to numerically simulate strength distribution in a powder metallurgy (P/M) compact. A 2-D Finite element model is carried out to simulate the flow behaviours of green aluminium powder compacts. The complicated case of green aluminium powder makes it is difficult from metalwork point of view to get analytical or empirical model to predict the compacts strength. Therefore, Cold Compression test is simulated using the 2-d model with ABAQUS software for compacted aluminium plate. Moreover, fracture toughness of the compacted aluminium powder is calculated using 2- D J-integral finite element model implemented into ABAQUS commercial. The results are in good agreement with the experimental ones and give a valuable graph decrypting the flow behaviour of the green compacts. The calculated fracture toughness of compacted aluminium powder is nearly

Keywords:
J-integral Compact tension powder metallurgy Finite element

This work is licensed under a Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/

Figures

References:

[1]	W.H. Hunt, New directions in aluminum-based P/M materials for automotive applications, International Journal of Powder Metallurgy 36, Pp. 50-56, 2000.
[2]	Sridhar, I., and N. A. Fleck. “Yield behaviour of cold compacted composite powders.” Actamaterialia 48.13, Pp. 3341-3352, 2000.‏
[3]	Mohamed. K. Hassan, Y. Mohammed, Abu El-Ainin H. Improvement of Al-6061 alloys mechanical properties by controlling processing parameters. International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol: 12 Issue: 02 pp.14-18, 2012.
[4]	Cunningham, J. C., Sinka, I. C., Zavaliangos, A.. Analysis of Tablet Compaction. I. Characterization of Mechanical Behavior of Powder and Powder/Tooling Friction. Journal of Pharmaceutical Sciences, 93,Pp. 2022-39, 2004.
[5]	Lee, S. C., Kim, K. T.. Densification behavior of aluminum alloy powder under cold compaction. International Journal of Mechanical Sciences, 44(7), 1295-1308, Pp. 2002.
[6]	Verma, Ranjit Kumar, N. S. Mahesh, and M. I. Anwar. “Numerical Analysis of Powder Compaction to Obtain High Relative Density in ‘601AB'Aluminum Powder.”‏ SASTECH, Volume 11, Issue 1, Apr 2012.
[7]	Youn, S., et al. “Aluminium powder forging process using a rotating platen.” Aluminium alloys: their physical and mechanical properties: proceedings of the 9th International Conference on aluminium alloys (ICAA9). Deakin University, School of Engineering and Technology, 2011.
[8]	Kim, K.. “A densification model for mixed metal powder under cold compaction”, International Journal of Mechanical Sciences, 2001.
[9]	Fleck, N. A. “On the cold compaction of powders.” Journal of the Mechanics and Physics of Solids 43.9, Pp. 1409-1431, 1995.‏
[10]	Martin, C. L., D. Bouvard, and S. Shima. “Study of particle rearrangement during powder compaction by the discrete element method.” Journal of the Mechanics and Physics of Solids 51.4, Pp. 667-693, 2003.‏
[11]	Fleck, N. A., B. Storåkers, and R. M. McMeeking. “The viscoplastic compaction of powders.” IUTAM Symposium on Mechanics of Granular and Porous Materials. Springer Netherlands, 1997.‏
[12]	Sinka, I. C. “Modelling powder compaction.” Kona 25 (2007): 4.‏
[13]	Choi, J. L., and D. T. Gethin. “A discrete finite element modelling and measurements for powder compaction.” Modelling and Simulation in Materials Science and Engineering 17.3, Pp. 035005, 2009.‏
[14]	Shang, C., I. C. Sinka, and J. Pan. “Constitutive Model Calibration for Powder Compaction Using Instrumented Die Testing.” Experimental mechanics 52.7,Pp. 903-916, 2012.
[15]	Cocks, A. C. F., et al. “Compaction models.” Modelling of Powder Die Compaction. Springer London, Pp. 43-64, 2008.‏
[16]	Schmidt, I., et al. “Simulation of the material behaviour of metal powder during compaction.” Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 224.3, Pp. 187-194, 2010.‏
[17]	Mohammed Y. Abdellah, M. Mahmoud Moustafa, Ashraf T. Mohamed, G. T. Abdel-Jaber, Wear Properties of Hot Extruded Aluminum Powder Compacts, Open Access Library Journal, 2014, PP. 1-6.
[18]	Abdellah, M. Y., Moustafa, M. M., & Mohamed, A. T.. Hot Extrusion of Reinforced Aluminum Powder Compacts. International Journal of Materials Lifetime, 1(1), 2014, 1-6.
[19]	N. S. Korim, M. Y. Abdellah, M. Dewidar and A. M. Abdelhaleem, “Crushable Finite Element Modeling of Mechanical Properties of Titanium Foam,” International Journal of Scientific & Engineering Research, vol. 6, no. 10, pp. 1221-1227, 2015.
[20]	Y. Mohammed, M. K. Hassan and A. M. Hashem, “Finite Element Computational Approach of Fracture Toughness in Composite Compact Tension Specimen,” International Journal of Mechanical & Mechatronics Engineering, vol. 12, no. 4, pp. 57-61, 2012.
[21]	Mohammed, Y., Moustafa, M.M., Mohamed, A.T. and Abdel-Jaber, G.T. (2014) Finite Element Analysis of Flow Behaviors of Aluminum Powder Compacts. IJARES International Journal of Applied Research in Engineering and Science, 1, 1-10.
[22]	G. E. Dieter, “Mechanical Metallurgy”, McGrow Hill Book Co., 1988.
[23]	Ansys software 5.6.2, “tutorial”.
[24]	ABAQUS, Version “6.9 Documentation.”, Providence, RI: Dassault Systemes Simulia Corporation, 2009.
[25]	C. S. Kanga, S. C. Leea, K. T. Kima, and O.Rozenberg, “Densification behaviour of iron powder during cold stepped compaction”, Materials Science and Engineering, A 452-453, pp. 359-366, 2007.
[26]	J. Lemaitre and J. L. Chaboche, “Mechanics of solid materials”, Cambridge University press, translated by B. Shrivastava, pp. 168-169, 1990.
[27]	Astm, “D 5045-96, Standard Test Method for Plane-Strain Fracture Toughness and Strain Energy Release Rate of Plastic Materials.”, Philadelphia: American Society for Tensting and Materials,199.