A Numerical Investigation of Alumina Powder Deformation Behaviors During Press Compaction Assisted Binder Jetting

Abstract In this paper, the deformation behaviors of AL2O3 powder during press compaction assisted binder jetting is numerically investigated using ABAQUS FEM software. Firstly, a verification of the validity and usefulness of previously defined Drucker-Prager model parameters for a given AL2O3 powder is carried out via a three-dimensional dynamic compression test in which simulation results were compared to results available in literature [1]. Total deformation, reaction forces, and the von Mises stress are examined and thoroughly scrutinized in order to understand ways in which compaction occurs in AL2O3 powder. Convergence of the defined compaction model is also ensured to provide assurance of reliability of the numerical results and further the understanding of validity of our conclusions. Then the deformation behaviors of this AL2O3 powder during press compaction assisted binder jetting is assessed numerically. The numerical results provide numerous implications for future research on press compaction assisted binder jetting. Conclusive results in the form of von Mises stress profiles and reaction force profiles in relation to compacted powder thickness are presented. The correlation between von Mises and reaction force were observed to be inverse with powder bed thickness, reaching maximums when the powder was compacted to roughly 25 micrometers. Decompression of the powder bed is also examined to provide key insights into the conditions in which binder jetting would occur. Elastic recovery was observed in the AL2O3 powder when build plate displacement direction is reversed.