A knowledge based system for optimum and concurrent design, and manufacture by powder metallurgy technology

This paper describes the elements of a prototype knowledge based system (KBS), which have been developed to provide advice relating to the manufacture of components through the use of powder metallurgy (PM) technology. The system comprises modules which address the following three important areas of product development: component design; materials selection; and powder packing and compaction. The design module employs a combination of feature based modelling and rule based design analysis, to assist with PM design optimization. Materials selection advice is generated through utilization of empirical rules relating, for example, the tensile strength of PM steels to their density and percentage carbon content. The third KBS module is concerned with quantification of the effects of variation in various critical powder packing and compaction parameters. A deficiency was identified in the existing knowledge relating to the effects on packing density, of combinations of more than one particle size, and particle irregularity. Consequently new modelling techniques have been developed which employ Monte Carlo type simulations for prediction of powder packing behaviour. It is expected that future developments based upon the methodologies described here, will enable production of comprehensive KBS modules, able to advise on optimum and concurrent design and manufacture of powder metallurgy components.