This study investigates the compaction of iron-based powders to produce high-density components with enhanced mechanical properties. A mathematical model analyzes stress distribution, porosity, and deformation under different pressing schemes, considering the influence of external friction. The solution reveals that pressing kinematics depend on process parameters but not on the loading surface type. Analytical results align with experiments, demonstrating distinct layer deformation patterns in one-sided, two-sided, and floating die pressing. The findings provide insights for optimizing powder metallurgy processes to minimize defects and achieve near-theoretical density in industrial applications.
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