Numerical investigation into the influence of the punch shape on the mechanical behavior of pharmaceutical powders during compaction

Abstract

During the production of pharmaceutical tablets using powder compaction, certain common problems can occur, such as sticking, tearing, cutting, and lamination. In the past, the compressibility of the powder was calculated only along the axis of the device; consequently, critical areas of the material throughout the volume could not be identified. Therefore, finite element method (FEM) can be used to predict these defects in conjunction with the use of an appropriate constitutive model. This article summarizes the current research in the field of powder compaction, describes the Drucker–Prager Cap model calibration procedure and its implementation in FEM, and also examines the mechanical behavior of powder during compaction. In addition, the mechanical behavior of pharmaceutical powders in relation to changes in friction at the wall of the system is examined, and the dependence of lubrication effect on the geometry of the compaction space is also investigated. The influence of friction on the compaction process for the flat-face, flat-face radius edge, and standard convex tablets is examined while highlighting how the effects of friction change depending on the shape of these tablets.