Abstract
Phenomenological plasticity models that relate relative density to plastic strain are frequently used to simulate ceramic powder compaction. With respect to the form implemented in finite element codes, they need to be modified in order to define governing parameters as functions of relative densities. Such a modification increases the number of constitutive parameters and makes their calibration a demanding task that involves a large number of experiments. The novel calibration procedure investigated in this paper is based on inverse analysis methodology, centered on the minimization of a discrepancy function that quantifies the difference between experimentally measured and numerically computed quantities. In order to capture the influence of sought parameters on measured quantities, three different geometries of die and punches are proposed, resulting from a sensitivity analysis performed using numerical simulations of the test. The formulated calibration protocol requires only data that can be collected during the compaction test and, thus, involves a relatively smaller number of experiments. The developed procedure is tested on an alumina powder mixture, used for refractory products, by making a reference to the modified Drucker–Prager Cap model. The assessed parameters are compared to reference values, obtained through more laborious destructive tests performed on green bodies, and are further used to simulate the compaction test with arbitrary geometries. Both comparisons evidenced excellent agreement.
Highlights
The ceramic industry includes the production of various components with different engineering applications, ranging from simple ones, such as tiles and bricks, up to more sophisticated ones, represented by refractory products, aerospace components, devices for bio-applications, etc
Such simulations are of major importance in the manufacturing of advanced components, such as those used in refractory applications for the control of liquid iron flow, those designed to work in aggressive environments and those subjected to severe thermo-mechanical loadings [10,11]
Theare constitutive models with large number of governing calibration such models through inverse analysis methodology to be rather frequentlyofemployed within the simulations of the ceramic powderproved compaction process
Summary
The ceramic industry includes the production of various components with different engineering applications, ranging from simple ones, such as tiles and bricks, up to more sophisticated ones, represented by refractory products, aerospace components, devices for bio-applications, etc. In contrast to certain previous studies that used a similar approach (e.g., [21,23,24]), a larger diversity of experimental data is included in this study by simultaneously considering different geometries within the calibration phase This diversity should serve to “activate” all the material parameters so that their assessed values can be treated as a representative one, rather than fitting a single experiment only. In order to ascertain the influence of sought parameters to the measurable quantities (here, the force–displacement relationship), numerical sensitivity analyses are first performed Such analyses result in the formulation of three different die/punch geometries, which prove to be sufficient to calibrate the considered constitutive model. The comparative analysis serves as a quantitative basis for the discussion of advantages and limitations of the proposed method
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