Theory of Force Transducer Design Optimization for Die Wall Stress Measurement During Tablet Compaction: Optimization and Validation of Split-Web Die Using Finite Element Analysis

Purpose. 1) To illustrate how computer aided engineering stress analysis can be used to improve the transducer design process for tablet press instrumentation; 2) to use these optimal design procedures for the geometric optimization of a cylindrical, segmented, and a novel split-web die design. Discussion includes the selection of optimal die wall thickness, segment cutting angle, strain gage placement, Wheatstone bridge configuration, and the influence of tablet height and position within the die on signal output.Methods. Stress analysis was done with a finite element analysis (FEA) software package running on a personal computer.Results. For the segmented die, the admissible range of die wall thicknesses depends upon cutting angle; the signal output is non-linear because the stress distribution in the die wall is influenced by tablet height and position within the die. For the split-web die, the optimal configuration consists of a 1/8 in. sensing web with a strain gage located at the peak of the sensing-web arch. This prototype had a linear calibration curve (r² = 0.999) with no hysteresis. Radial versus axial stress transmission curves for: starch and sodium chloride were consistent with literature data.Conclusions. Finite element analysis (FEA) is a useful numerical tool for the systematic optimization of tablet press instrumentation. By enclosing the sensing web of a three layered die design in a cylinder, the split-web design can be directly mounted without modification of the die table.