Finite Element Simulation of the Compaction of Aluminum-Based PM Gears

PM alloys, especially aluminum PM (Al PM), are coming to the forefront of automotive design, as light-weight parts are desired in the overall goal of increased fuel efficiency. Since Al PM use is relatively new, the current modeling of its compaction processes and the material behaviour are not widely reported, especially for complex shapes such as gears. Successful simulation of the compaction of a gear with an involute profile was conducted in 3D and the density distribution was predicted. The results are consistent with those found for simpler geometries such as cylinders and identify potential locations of large gradients (changes) in density.