Densification Mechanism of Soft Magnetic Composites Using Ultrasonic Compaction for Motors in EV Platforms

In this paper, the densification mechanism of ultrasonic compaction was analyzed using a force balance model. Ultrasonic compaction is quite a promising way to solve the lower mechanical property problem of green compact in the compaction process, although it has some obstacles to overcome for its various applications. Our model proposes that the resultant density is achieved as the applied and resistance forces reach the equilibrium state. Based on the proposed model, the ultrasonic compaction increases the density of green compact by reducing the internal friction between the powder and compaction die, as well as the internal friction among particles themselves. It was also found that during the powder compaction, the ultrasonic vibration mostly contributes to slipping and the rearrangement of the particles.