Modeling the Process of Pressing Powdered Aluminum with Calcium Carbonate

This paper examines the technological and numerical aspects of compacting aluminum powder with pore-forming calcium carbonate. It is shown that the addition of CaCO₃ to the powder mixture increases the overall porosity of the sintered composite, affecting the density and mechanical properties of the material. To describe the compaction process, the Heckel model implemented in Mathcad was used, which made it possible to calculate the change in relative density with increasing compaction pressure. Numerical modeling was also performed in ANSYS Mechanical using the density-dependent Drucker–Prager Cap model. The obtained calculations showed a characteristic density distribution: the area near the punch reaches maximum density, and the opposite end reaches minimum density. A significant influence of friction on compaction heterogeneity (a drop in pressure and density of up to ≈10 % along the height) was revealed, and the exponential dependence of density on compaction pressure was confirmed. Comparison of the results of mathematical models and FEM analyses allows us to predict the optimal conditions for pressing powder composites to obtain a homogeneous structure and the required properties of the material.