Simultaneous deposition of powder in three parallel-oriented cylindrical dies

The inhomogeneity of bulk density distribution created during the die filling process might cause quality problems for powder compacts, such as distortion, lamination, and cracking. To avoid these problems, understanding the die filling process and ensuring a uniform pre-compaction powder deposition are necessary. The second-generation pressure deposition tester (PDT-II) was developed to investigate simultaneous deposition of powder into multiple dies. Its design requirements and new features were proposed through evaluating the main strength and limitations of the mass deposition tester (MDT). The operation of the PDT-II and analysis of its data showed that it generates real-time deposition profiles of the entire process for multiple locations. PDT-II data can be used to study the effects of various filling-related parameters (such as die shape, powder flowability, and feed shoe speed) on the deposition process and final pressure distribution. For cylindrical dies filled with a granulated powder with d50 = 600 μm (1) at low feed shoe speeds (20 and 100 mm/s), the half circle close to the leeward end had higher final pressure values than the forward half circle; (2) at high feed shoe speed (500 mm/s), the final pressure distribution was more uniform than at lower feed shoe speed; (3) the final within-die pressure distribution at the bottom of the dies was not always symmetrical about the center line of the feed shoe movement direction, even though sometimes it was quite symmetrical; (4) the overall trend was that pressure decreases with increasing radial distance for lower feed shoe speeds; and (5) higher feed shoe speed (500 mm/s) resulted in higher final pressure values (774.5 to 1424.5 Pa) than lower feed shoe speeds (20 and 100 mm/s) (235.2 to 1136.0 Pa) at most of the locations. The results proved that feed shoe speed does have an effect on pressure distribution and its uniformity.