Numerical modelling of contact adhesion in a random assembly of elastic–plastic particles.

The prediction of tensile strength properties of powder compacts remains an important industrial issue. In particular, one of the main problems of the powder compaction process is the failure of compacts. Indeed, some powder compacts exhibit cracks which appear during compaction. Such defects occur due to localised tensile or shear stresses, for example close to geometrical singularities. They are also related to the ability of a powder to create enough adhesion at contacts between particles to withstand tensile stresses. Therefore, cracks are a consequence of phenomena occurring at the particle scale and below, down to the molecular scale. To help understanding this mechanism, a particle-scale, numerical method called the multi-particle finite-element method was developed using the finite-element software suite Abaqus (Abaqus 6.14 Documentation, 2016). Such a method allowed to explicitly model the microstructure of a granular media idealised as an assembly of elastic–plastic spheres. The particles were meshed such that their deformations were fully taken into account, using a continuum-mechanics-based material model. The interactions between particles were managed using finite-element contact formulations. A multi-scale, adhesive contact model was developed based on the literature and implemented into the multi-particle finite-element code. The contact model was based on a surface energy formulation weighted by the roughness model developed by Pullen and Williamson (1972). It introduced a novel aspect, the development of adhesion under the effect of external mechanical loads, which is consistent with the cold compaction process. This model was then applied to predict the mesoscopic properties of a packing of spheres, i.e. its response to mechanical stresses of any type, in particular strongly deviatoric stress paths. Such a method intends to be a help toward the development of an efficient continuum model for the modelling of the powder compaction process. • Contact adhesion was implemented into the multi-particle finite-element method. • A new adhesive contact model including the effect of surface roughness was developed. • It was validated against existing adhesive, elastic–plastic contact models. • Adhesion had an influence on yield properties under tensile and shear loading paths. [ABSTRACT FROM AUTHOR]