Dear Raju,

First of all, you need to find the suitable pressure regardless the thickness. To do so:

1- make few pellets using different values of pressure.

2- calculate the green density of the pellets.

3- draw a graph using the pressure in the x-axis and the green density in the y-axis. You will notice that when the pressure is increased the green density will also increase till it reaches almost a constant value (the highest green density).

4- The suitable pressure is the minimum pressure that produces a pellet with green density close to the highest green density without cracks.

Once you find the suitable pressure, you can prepare new set of pellets using the suitable pressure and different amounts of the powder. Again, you can draw a graph between the amount of the powder on the x-axis and the thickness on the y-axis. you can use this graph to estimate the required amount of powder for any desired thickness.

Please note that binders and/or lubricants may be needed to obtain pellets with high green strength and free of cracks.

Thank you sir.How to find out green density.is there any direct formulas to find the load by knowing weight and diameter

The behaviour of every material to the applied load is different, also the factors like temperature, time of holding, powder particle size, moisture in the powder (if any) can make difference in the values of the applied load for making the highest density green sinter. So, I would advice you to go for the procedure as mentioned by @ Imad. Its not necessary that you start from load, you can also start from whatever the maximum load you have and come to lower loads. wherever you find decrease in the green density, stop.

How to produce uniform thickness of the pellet.

You have to do some trail and error to get the maximum green density. While applying load, loading cycle should be in such a way that the load should be applied gradually and mantain load followed by very slow release.

There is no direct way to find the load required. Archemedis principle is the startdard way to measure green density.

I would suggest you to start with a load that was reported in the literature for the powder you were using.

following