A full 3D finite element analysis of the powder injection molding filling process including slip phenomena

Hwang, Chul-Jin; Kwon, Tai Hun

doi:10.1002/pen.10926

Cited by 25 publications

(7 citation statements)

References 16 publications

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“…Ilinca et al [2] also allowed a yield stress in the viscosity model, and solved the energy equation to include the nonisothermal effects. Kwon and co-workers [4,5] investigated the rheological characterization of the powder/binder mixtures in the powder injection molding, especially for the quantitative characterization of the slip phenomena on the mold wall. A three-dimensional finite element analysis of the powder injection molding filling process including the slip phenomena was also discussed in reference [5].…”

Section: Introductionmentioning

confidence: 99%

Simulation of Core Deflection in Powder Injection Molding

Ling

Gupta

Myers

et al. 2006

International Polymer Processing

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Core deflection in powder injection molding is one of the main causes of the structural defects in the molded part. Simulation of the core deflection in the injection molding process requires solution of the fluid-solid interaction problem, in which the fluid flow and solid deformation problems are coupled along the fluid-solid interface. A three-dimensional finite element program was developed in this work for a non-isothermal injection molding simulation including the fluid-solid interaction effects. With the assumption of small deformation in the solid structure, the fluid flow problem is formulated in an Eulerian frame-work, whereas the solid structure problem is formulated in a Lagrangian framework. Numerical simulation of the filling stage of injection molding for an airfoil-shaped part is presented and compared with the experimental data. The predicted melt-front advancement as well as the pressure is in good agreement with the corresponding experimental results. The predicted core deflection during the filling stage of the injection molding process is also compared with the measurements on a molded part.

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Section: Introductionmentioning

confidence: 99%

Simulation of Core Deflection in Powder Injection Molding

Ling

Gupta

Myers

et al. 2006

International Polymer Processing

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“…Significant progress has been made in the last few years in the computer modeling of most aspects of the PIM process, from the tool design [9,10], feedstock preparation [1,11-14], heat transfer [15], injection molding stage [1,4,7,10,14, [16][17][18][19][20][21][22], and powderbinder separation [2,8,23], to debinding [24][25][26][27][28], and sintering [29][30][31][32][33][34]. However, most of these are still in the research and development phase, and have not been applied on actual production cases.…”

Section: Introductionmentioning

confidence: 99%

Optimization of the Powder Injection Molding Process Parameters Using the Sequential Simplex Algorithm and Sensitivity Analysis

Panahi¹,

Mianajiy²,

Miandoabchi³

et al. 2013

Journal of Manufacturing Science and Engineering

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In this work, the minimization of warpage was investigated using the "MOLDFLOW" software and sequential simplex algorithm based on feedstock properties. Also, the sensitivity analysis was implemented to determine the degree of impact of each parameter on the warpage. This study is divided into two portions: experimental analysis and numerical analysis. First, for the experimental study, four kinds of feedstock with different alumina powder loadings were prepared to investigate the rheological properties. This investigation showed that the feedstock with 60 vol. % alumina powder was the optimum feedstock for the injection molding. Also, the results indicated that the viscosity of feedstock decreases by increasing both the shear rate and temperature. Next, the thermal conductivity of this feedstock was measured at different temperatures and it was found that the change of temperature can greatly influence the thermal conductivity of feedstock. In the numerical study, the injection molding parameters were divided into three categories. Based on the feedstock properties obtained form the first portion, and in order to minimize the warpage, the values of these parameters were sequentially acquired by MOLD-FLOW and used in the sequential simplex algorithm for gradual convergence to the optimum level. To show the accuracy of numerical results, several samples were injection molded using the injection molding conditions for each vertex; results showed a close correlation between the values obtained by the numerical simulation and by the actual case. After determining the optimum parameter values, the sensitivity analysis was performed to identify the level of influence of each parameter on warpage. The obtained results showed that the most effective parameters on warpage are the mold temperature, packing pressure, and the holding time. Generally, it is demonstrated that the experimental and numerical analysis, performed via the MOLDFLOW software and sequential simplex algorithm, together with the sensitivity analysis can be useful in achieving success in the powder injection molding (PIM) technique.

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“…There has been some development recently in this direction [2][3][4] . Researchers are beginning to realize the importance of the 3D flow simulation, especially for the fluids with complex rheological behavior.…”

Section: Introductionmentioning

confidence: 99%

3D Flow Simulation for Viscous Nonisothermal Incompressible Fluid in Injection Molding

Cao

Shen

Wang

2005

Polymer-Plastics Technology and Engineering

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The major drawbacks of the Hele-Shaw approximation, commonly used today as a means of simplifying the simulation of the injection molding process, are the inherent loss of the ability to predict important physical phenomena and the ambiguity involved in the definition of a midplane. With the objective of eliminating many of these problems, a fully three-dimensional mold filling simulation program has been developed. The governing equations are in terms of Navier-Stokes problems for the viscous, incompressible, nonisothermal, and non-Newtonian fluid. To avoid the simultaneous determination of the coupled velocity and pressure, this article introduces an iterative method that at any given time step solves the components independently. This method reduces memory needs in simulation and enhances the stability of numerical scheme. In addition, this article also presents a mixed implicit and ''up-wind'' scheme to discrete the energy equation. It can overcome the spatial oscillations of temperature in numerical simulation. Good agreements with both analytic solution and the actual processes are found in the current investigation. This method can successfully predict the flow features in injection molding.

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A full 3D finite element analysis of the powder injection molding filling process including slip phenomena

Cited by 25 publications

References 16 publications

Simulation of Core Deflection in Powder Injection Molding

Simulation of Core Deflection in Powder Injection Molding

Optimization of the Powder Injection Molding Process Parameters Using the Sequential Simplex Algorithm and Sensitivity Analysis

3D Flow Simulation for Viscous Nonisothermal Incompressible Fluid in Injection Molding

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