Determination of dynamic and sliding friction, and observation of stick-slip phenomenon on compacted polymer powders during high-velocity compaction

Abstract

Dynamic friction, sliding friction, and the stick-slip phenomenon have been studied on compacted polymer powders during high-velocity compaction. It is particularly important from a practical point of view to distinguish the stick-slip mechanism and the sliding mechanism which occur concurrently. A practical experimental system has been successfully developed to study the dry frictional force and to measure the sliding coefficient between the polymer powder particles and the die wall during high-velocity compaction. Two new components have been introduced as relaxation assists to improve the compaction process by reducing the frictional forces. It was found that the relaxation assist device leads to an improvement in the polymer powder compaction process by giving a more homogeneous opposite velocity and a better locking of the powder bed in the compacted form with less change in dimensions. The subsequent movement of the particles can be reduced and the powder bed attains a higher density with a minimum total elastic spring-back. The relative time of the stick-slip phenomenon during the compacting stage is also reduced so that the time needed to transfer from an intermittent stick-slip state to a smooth sliding state is reduced and the powder bed slides smoothly. It was found that the dynamic, dry frictional force is intermittent (stick-slip mechanism) at low compaction rates but that at high compaction rates is becomes more smooth (sliding mechanism). Both mechanisms depend on the nature of the powder and on the compaction conditions. At the beginning of the compaction stage, the sliding coefficient decreases due to an increase in the radial to axial stress ratio until the maximum pressure has been reached. During the reorganization stage, more time is needed for large particles to move, rotate and slide due to their relatively large diameter and mass. As a result, the reorganization stage is extended and the stick-slip phenomenon is observed more with increasing particle size. Much better transfer of the pressure throughout the powder bed and less loss of pressure lead to a higher sliding coefficient due to the overall friction during the compaction process. It was found that the sliding coefficient is proportional to the density. A more homogeneous density distribution in the compacted powder and a smaller pressure loss during compaction has a major influence on the sliding coefficient and on the quality of the compacted material.