SIMUDENS -- An Advanced FEM Framework For Sintering: Automated Material Calibration And Geometry Compensation For First-Time-Right Manufacturing

Abstract

This study presents SIMUDENS, an advanced Finite Element Method (FEM) framework designed to simulate the sintering behaviour of powder metallurgy components, specifically targeting Binder Jetting and Metal Injection Moulding. The tool implements a phenomenological sintering model via a UMAT user subroutine, compatible with both Abaqus and the open-source solver Calculix. The framework integrates two innovative modules: an iterative optimization module for automated material calibration and an "inverse problem" solver for algorithmic geometry compensation. The tool's predictive accuracy was validated using real Binder Jetting samples manufactured and sintered by AMES. By first calibrating the material parameters and subsequently optimizing the green geometry, a "first-time-right" manufacturing strategy was achieved. Experimental results demonstrate high fidelity in reproducing final part shapes, significantly reducing trial-and-error costs, and accelerating the development of high-precision components.