On the simulation of molded micro components and systems

Abstract

Regarding micro components and systems, experimental work for characterizing materials' properties as well as components' and systems' behaviors have to be supplemented by numerical analyses. These analyses should cover component and system issues. On a component level, macroscopic approaches are extended by methods allowing consideration of the influence of components' grain structures including possible defects. On a system level, the high tolerances accepted for the individual components due to production inaccuracy and their effects on the expected load distribution capability of the system are taken into account. This paper presents approaches for simulation of micro components and systems using the finite element method and multi body simulation. Methods to overcome the abovementioned issues will be shown, as well as the effects of grain structure on the stress distribution in the individual components.

Methods for simulating and optimizing molded micro components and systems

“…A complete model description can be found in Albers et al (2008d). Difficulties arose with the introduction of the gear profile parameters.…”

“…The flank geometry modeled, thus being parametric, is still away from the real profiles measured on probes (Albers et al 2008c). Selection of the best simulation methodology to perform the system simulations is based on previous research work by the group (Albers et al 2008a). A blend of the finite elements models and the multi body simulation (MBS) approaches unites the benefits of a detailed and precise geometry discretization with the superior contact and dynamic capabilities of MBS, all combined with short solving times.…”

“…In literature, several models for polycrystalline components can be found. In this paper, FE based method described in Albers et al (2008a) has been used. This method can be applied not only to representative volume elements but also to complex threedimensional components.…”

Micro gear validation: improving the correlation between virtual and physical testing

“…Therefore a very advantageous approximation can be achieved for the simulation process. It is possible to consider each test run as a sequence of static load cases (Albers et al 2008b). Thanks to this 'static' nature of the problem an alternative path is followed to perform the simulations, using commercially available FEA solvers to create a model that resembles a Multi Body Simulation model without their limitations regarding to external geometry.…”

An integrated approach for validating micro mechanical systems based on simulation and test

“…The runs have been simulated with slow rotational speed, so to keep the inertial forces as low as possible. From a numerical point of view, it is then possible to consider the test as a sequence of static load cases (Albers et al 2007b). The pressing force acting on the flanks has been kept as low as possible, in order to avoid deformation on the profile of the teeth.…”