Numerical simulation of die compaction and sintering

A method to simulate die compaction and sintering is presented. By implementing user defined routines for both processes into the general purpose finite element program ABAQUS quantitative predictions of density distributions and shape distortions can be obtained as well as the stresses in the tool components. By computational optimisation of the individual production steps suggestions can be made to improve the final properties. As an example for both die pressing and sintering a complex three-dimensional part is simulated and suggestions to improve dimensional accuracy are made. Finally, stresses in the tools are calculated showing that the deflections are large enough to cause punch to punch contact so that tool wear must be expected.