Two-Piece Compaction Die Design
ORNL/TM-2010/48 described some results from using the finite element program ANSYS to determine the design geometry for compaction dies used to create europium oxide and tantalum control plates. Because of some discrepancies between the final drawings of the parts and the TM analyses, the models were reworked and some design modifications were made. When the mesh density was increased, increasing the number of elements in the model, especially near the corners, the maximum stresses in the corners were found to be higher than in the previous study. The dies needed to be designed with inner corner radii and interference fits that would allow the necessary compression force to create the plates but not exceed the yield strength of the material. Also, modeling was done to determine the effects of loading the dies asymmetrically in the axial direction, as this would make the plate extraction process easier while increasing the stress in the corners. The results show that for the tantalum die, a diametrical interference fit of 0.0020 in. between the outer ring and the insert is acceptable, and the inner corner radius can be as small as 0.0035 in. The insert has an outer diameter of 6.150 in. The cavity in the insert is 3.4640 $\times$ 0.8086 ± 0.002 in. and the outer ring has an outer diameter of 8.150 in. The die is 2.960 in. deep. With these design parameters, the plate can be formed so that its edge is 0.500 in. from the top or the bottom of the die, and the maximum stress everywhere in the die will be less than the yield strength of the materials. For the europium oxide die, the diametrical interference fit between the outer ring and the insert must be between 0.0075 and 0.0080 in. The inner corner radius can be as small as 0.0055 in. The insert has an outer diameter of 5.960 in. The cavity in the insert is 3.4552 $\times$ 1.7246 ± 0.002 in. and the outer ring has an outer diameter of 8.150 in. The die is 3.020 in. deep. With these design parameters, the plate can be formed so that its edge is 1.225 in. from the top or the bottom of the die.