Elastic Die Technology for Spur Gear Powder Compaction: Experimental Measurements and Simulation-Based Validation

Achieving high density in complex powder metallurgy components like spur gears is often hindered by friction-induced density gradients and ejection defects. This study investigates a novel elastic die system designed to mitigate these issues through controlled radial deformation. Spur gears were compacted using Ancorsteel 2000 powder under pressures of 400–700 MPa, utilizing a tapered elastic sleeve to apply radial compression. Green and sintered densities were measured, while porosity distribution was quantified via image analysis. Additionally, a 3D finite element simulation using FORGE software was conducted to model the thermo-mechanical behavior and stress distribution during the process. Experimental trials demonstrated that the elastic relaxation of the sleeve enabled free ejection of the compacts without requiring extraction force. Image analysis confirmed a homogenous porosity distribution across the gear teeth, and higher die pre-stressing strokes were found to correlate with increased sintered density. Finite element modeling accurately predicted critical stress concentrations of 700 MPa at the die-sleeve interface and validated the strain distribution. The results confirm that elastic die technology effectively eliminates ejection friction and improves density uniformity in complex gears, offering a viable solution for reducing tool wear and manufacturing defects in high-precision powder metallurgy.