In order to optimize the process parameters of ceramic powder compaction, a process simulation was first performed using a finite element method. In the finite element analysis, a quasi-random multi-particle array was introduced for modeling the non-periodic and randomly scattered powder particles with initially-low relative densities. Homogenization theory was employed to find the equivalent material properties associated with various porosities. The size of Al2O3 particles, amplitude of the cyclic compaction pressure, and friction coefficient among powder particles were chosen as process parameters. Finite element analysis results show that relative density becomes bigger as the process variables become smaller. Next, a regression model was found by using the response surface method, based on the results of the finite element analysis. Then, the optimal conditions of the process parameters providing the highest relative density were pursued by employing a grid search method.

Keywords: Ceramic powder compaction, Homogenization method, Process parameter ptimization, Relative density, Response surface method, Grid search method, Finite element analysis.