A plasticity model for powder compaction processes incorporating particle deformation and rearrangement

This paper develops a mechanistic model of granular materials that can be used with a commercial finite element package (ABAQUS). The model draws on the ideas of critical state soil mechanics and combines them with the theory of envelopes to develop an elasto-plastic model with a non-associated flow rule. The model incorporates both local deformation at the granule contacts, and rearrangement of the granules so that jointly they account for any bulk deformation. The mechanics of the model closely reflect the physicality of the material behaviour and the model parameters are closely linked (although not simplistically identical) to the characteristics of the granules. This not only gives an insight into the material behaviour, but also enables the model to be used to facilitate design of the material, its processing properties and, hence, component development. The model is used to simulate drained triaxial tests, settlement of a powder in a bin, and some examples of die pressing. Simulations are compared with experimental data and with predictions obtained using other models.