A novel method for the quantitative characterization of the simultaneous plasticizing and filling performance in ultrasonic plasticization micro injection molding

Zou, Yang; Wu, Wangqing; Xiao-tian, Zhou; Wei, Guomeng; Jiang, Bingyan

doi:10.1016/j.matdes.2021.109680

Cited by 12 publications

(7 citation statements)

References 27 publications

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“…The injection molding technology for conventional gears is mature and can basically meet the use requirements. However, for micro-nano manufacturing grade small module plastic gears (gears with module less than or equal to 1 mm are usually called small module gears), there are still many challenges to be addressed in micro-injection molding [ 12 , 13 ]. The biggest issue faced by small module plastic gears is the serious shortage of dimensional accuracy.…”

Section: Introductionmentioning

confidence: 99%

A Practical Numerical Approach to Characterizing Non-Linear Shrinkage and Optimizing Dimensional Deviation of Injection-Molded Small Module Plastic Gears

2021

Polymers

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This paper was aimed at finding out the solution to the problem of insufficient dimensional accuracy caused by non-linear shrinkage deformation during injection molding of small module plastic gears. A practical numerical approach was proposed to characterize the non-linear shrinkage and optimize the dimensional deviation of the small module plastic gears. Specifically, Moldflow analysis was applied to visually simulate the shrinkage process of small module plastic gears during injection molding. A 3D shrinkage gear model was obtained and exported to compare with the designed gear model. After analyzing the non-linear shrinkage characteristics, the dimensional deviation of the addendum circle diameter and root circle diameter was investigated by orthogonal experiments. In the end, a high-speed cooling concept for the mold plate and the gear cavity was proposed to optimize the dimensional deviation. It was confirmed that the cooling rate is the most influential factor on the non-linear shrinkage of the injection-molded small module plastic gears. The dimensional deviation of the addendum circle diameter and the root circle diameter can be reduced by 22.79% and 22.99% with the proposed high-speed cooling concept, respectively.

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Section: Introductionmentioning

confidence: 99%

A Practical Numerical Approach to Characterizing Non-Linear Shrinkage and Optimizing Dimensional Deviation of Injection-Molded Small Module Plastic Gears

2021

Polymers

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“…This technology can not only directly reflect the relationship between process parameters and the quality of molded parts but also meet the indicators of stabilizing part quality and tracing part defects. Wu et al [ 135 ] proposed a new method to quantitatively characterize the efficiency of simultaneous plasticization and filling by redefining the injection rate as the mass flow during melt filling. The results show that without damaging the mechanical properties of the micro-molded samples, increasing the injection rate is beneficial to simultaneously increasing the efficiency of plasticization and filling.…”

Section: Ultrasonic Plasticization Micro-injection Moldingmentioning

confidence: 99%

Tuning Power Ultrasound for Enhanced Performance of Thermoplastic Micro-Injection Molding: Principles, Methods, and Performances

Zhao

Qiang

et al. 2021

Polymers

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With the wide application of Micro-Electro-Mechanical Systems (MEMSs), especially the rapid development of wearable flexible electronics technology, the efficient production of micro-parts with thermoplastic polymers will be the core technology of the harvesting market. However, it is significantly restrained by the limitations of the traditional micro-injection-molding (MIM) process, such as replication fidelity, material utilization, and energy consumption. Currently, the increasing investigation has been focused on the ultrasonic-assisted micro-injection molding (UAMIM) and ultrasonic plasticization micro-injection molding (UPMIM), which has the advantages of new plasticization principle, high replication fidelity, and cost-effectiveness. The aim of this review is to present the latest research activities on the action mechanism of power ultrasound in various polymer micro-molding processes. At the beginning of this review, the physical changes, chemical changes, and morphological evolution mechanism of various thermoplastic polymers under different application modes of ultrasonic energy field are introduced. Subsequently, the process principles, characteristics, and latest developments of UAMIM and UPMIM are scientifically summarized. Particularly, some representative performance advantages of different polymers based on ultrasonic plasticization are further exemplified with a deeper understanding of polymer–MIM relationships. Finally, the challenges and opportunities of power ultrasound in MIM are prospected, such as the mechanism understanding and commercial application.

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“…Plastic pellets, for example, can be successfully conveyed in the plasticizing unit of injection/extrusion molding machines by customizing the interfacial friction between the barrel and the screw [ 1 , 2 ]. With its benefits of rapid heat generation, low energy consumption, and high material usage rate, ultrasonic plasticization microinjection molding (UPMIM) technology has recently become an appealing version of thermoplastic microinjection molding [ 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 ]. Interfacial friction in UPMIM plasticizing units has aroused researchers’ curiosity to understand the quick heat generating mechanism [ 11 , 12 , 13 , 14 , 15 , 16 , 17 ].…”

Section: Introductionmentioning

confidence: 99%

Polymer–Metal Interfacial Friction Characteristics under Ultrasonic Plasticizing Conditions: A United-Atom Molecular Dynamics Study

Changsheng

Qiang

et al. 2022

IJMS

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Understanding the properties of polymer–metal interfacial friction is critical for accurate prototype design and process control in polymer-based advanced manufacturing. The transient polymer–metal interfacial friction characteristics are investigated using united-atom molecular dynamics in this study, which is under the boundary conditions of single sliding friction (SSF) and reciprocating sliding friction (RSF). It reflects the polymer–metal interaction under the conditions of initial compaction and ultrasonic vibration, so that the heat generation mechanism of ultrasonic plasticization microinjection molding (UPMIM) is explored. The contact mechanics, polymer segment rearrangement, and frictional energy transfer features of polymer–metal interface friction are investigated. The results reveal that, in both SSF and RSF modes, the sliding rate has a considerable impact on the dynamic response of the interfacial friction force, where the amplitude has a response time of about 0.6 ns to the friction. The high frequency movement of the polymer segment caused by dynamic interfacial friction may result in the formation of a new coupled interface. Frictional energy transfer is mainly characterized by dihedral and kinetic energy transitions in polymer chains. Our findings also show that the ultrasonic amplitude has a greater impact on polymer–metal interfacial friction heating than the frequency, as much as it does under ultrasonic plasticizing circumstances on the homogeneous polymer–polymer interface. Even if there are differences in thermophysical properties at the heterointerface, transient heating will still cause heat accumulation at the interface with a temperature difference of around 35 K.

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A novel method for the quantitative characterization of the simultaneous plasticizing and filling performance in ultrasonic plasticization micro injection molding

Cited by 12 publications

References 27 publications

A Practical Numerical Approach to Characterizing Non-Linear Shrinkage and Optimizing Dimensional Deviation of Injection-Molded Small Module Plastic Gears

A Practical Numerical Approach to Characterizing Non-Linear Shrinkage and Optimizing Dimensional Deviation of Injection-Molded Small Module Plastic Gears

Tuning Power Ultrasound for Enhanced Performance of Thermoplastic Micro-Injection Molding: Principles, Methods, and Performances

Polymer–Metal Interfacial Friction Characteristics under Ultrasonic Plasticizing Conditions: A United-Atom Molecular Dynamics Study

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