A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications...A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications, was selected as a model pattern. The prism pattern is 50 μm in pitch and 108° in the vertical angle. The overall size of the plate was 335 mm×213 mm and the thickness of the plate varied linearly from 2.6 mm to 0.7 mm. The prism pattern was firstly machined on the nickel plated core block using micro diamond tool and this machined pattern core was installed in a mold for injection molding of prism patterned plate. Polymethyl methacrylate (PMMA) was used as a molding material. The pressure and temperature of the melt in the cavity were measured at different positions in the cavity and the replication of the pattern was also measured at the same positions. The results show that the pressure or temperature profile through the process depends on the shape and the size of the plate. The replication is affected by the temperature and pressure profiles at the early stage of filling, which is right after the melt reaches the position to be measured.展开更多
In order to reduce the "trial-mold" risk and cost,numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 ...In order to reduce the "trial-mold" risk and cost,numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm(depth) ×0.4 mm(width) ×12 mm(length) in test area was selected as the objective part,and polypropylene(PP) as the experimental material. Respectively with specific commercial software(Mold Flow) and general computational fluid dynamic(CFD) software(Comsol Multiphysics) ,the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process,the specific commercial software for normal injection molding process is not valid to describe the micro flow process,the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle due to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development,the general CFD software,which is more flexible in user defining function,is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion,as for weld line forming process,the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process;but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.展开更多
Micro powder injection molding (μPIM) was investigated for possible mass production of micro-components at rela- tively low cost. However, scaling down to such a level produces challenges in injection molding and d...Micro powder injection molding (μPIM) was investigated for possible mass production of micro-components at rela- tively low cost. However, scaling down to such a level produces challenges in injection molding and debinding. Micro gears were fabricated by μPIM from in-house feedstock. The effect of injection speed and injection pressure on the replication of the micro gear cavity was investigated. Solvent debinding and thermal debinding processes were discussed. The results show that micro gears can be successfully fabricated under the injection pressure of 70 MPa and the 60% injection speed. Either too low or too high injection speed can cause incomplete filling of micro gears. The same is the case with too low injection pressure. Too high injection pressure can bring cracks. Solvent debinding of micro gears was performed in a mixture of petroleum ether and ethanol. Subsequently, micro gears were successfully debound by a multistep heating schedule.展开更多
The ceramic injection molding technique was used in the gas-pressure sintering of ultra-fine Si3N4 powder. The feedstock's flowability, debinding rate, defect evolution, and microstructural evolution during productio...The ceramic injection molding technique was used in the gas-pressure sintering of ultra-fine Si3N4 powder. The feedstock's flowability, debinding rate, defect evolution, and microstructural evolution during production were explored. The results show that the solid volume loading of less than 50vol% and the surfactant mass fraction of 6wt% result in a perfect flowability of feedstock; this feedstock is suitable for injection molding. When the debinding time is 8 h at 40°C, approximately 50% of the wax can be solvent debinded. Defects detected during the preparation are traced to improper injection parameters, mold design, debinding parameters, residual stress, or inhomogeneous composition distribution in the green body. The bulk density, Vickers hardness, and fracture toughness of the gas-pressure-sintered Si3N4 ceramic reach 3.2 g/cm^3, 16.5 GPa, and 7.2 MPa·m^1/2, respectively.展开更多
In the micro-molding of component with a micro-sized channel, the ability for polymer melt to flowing into the micro-channel in a macro-sized part is a big challenge. The multidimensional flow behaviors are included i...In the micro-molding of component with a micro-sized channel, the ability for polymer melt to flowing into the micro-channel in a macro-sized part is a big challenge. The multidimensional flow behaviors are included in the injection molding the macro-component with a micro-channel. In this case, a simplified model is used to analyze the flow behaviors of the macro-sized part within a micro-channel. The flow behaviors in the macro-cavity are estimated by using the finite element and finite difference methods. The influence of the injection rate, micro-channel size, heat transfer coefficient, and mold temperature on the flowing distance is investigated based on the non-isothermal analytic method. The results show that an increase in the radius of the micro-channel and mold temperature can improve effectively the flowing distance in the micro-channel.展开更多
Silicon carbide (SiC) is highly wear resistant with good mechanical properties, including high temperature strength, excellent chemical resistance, and high thermal conductivity and thermal shock resistance. SiC molds...Silicon carbide (SiC) is highly wear resistant with good mechanical properties, including high temperature strength, excellent chemical resistance, and high thermal conductivity and thermal shock resistance. SiC molds, which can be produced with diverse microstructural features, are now widely used in glass molding owing to their excellent characteristics, and also have potential applicability in IT industries. SiC molds are traditionally fabricated by silicon micromachining or dicing. The fabrication cost of silicon micromachining is very high, however, because several expensive masks are needed. Furthermore, the fabrication time is very long. Meanwhile, it is difficult to make micro-patterned molds with arbitrary shapes using dicing saws. Abrasive water jet (AWJ) is widely applied to cut and drill very brittle, soft and fibrous materials. It offers high energy density, the absence of a heat affected zone(HAZ), high performance, and an environment friendly process. In spite of these advantages, micro-hole drilling via conventional AWJ processing suffers from notable shortcomings. We proposed a new abrasive supplying method of AWJ. The proposed method reduces frosting phenomena, and provides micro-machining of AWJ. The characteristics of a hole machined was investigated by the proposed AWJ process according to the ratio of water and abrasives. With the optimal experimental conditions, 3×3 array SiC molds with the diameter of 700 μm and depth of 900 μm were successfully manufactured.展开更多
Micro powder injection molding (μPIM),a miniaturized variant of powder injection molding,has advantages of shape complexity,applicability to many materials and good mechanical properties. Co-injection molding has bee...Micro powder injection molding (μPIM),a miniaturized variant of powder injection molding,has advantages of shape complexity,applicability to many materials and good mechanical properties. Co-injection molding has been realized between met-als and ceramics on micro components,which become the first breakthrough within the PIM field. Combined with the prominent characteristics of high features/cost ratio,micro powder injection molding becomes a potential technique for large scale production of intricate and three-dimensional micro components or micro-structured components in microsystems technology (MST) field.展开更多
Replication processes for the manufacturing of micro/nano-structured components are characterized by a certain degree of precision and accuracy.The transcription loss,or replication fidelity,defines the geometrical an...Replication processes for the manufacturing of micro/nano-structured components are characterized by a certain degree of precision and accuracy.The transcription loss,or replication fidelity,defines the geometrical and dimensional correspondence of micro/nano-structure from metal tool inserts into plastic patterned products.The employment of a vast spectrum of micro/nano-structured geometries calls for methodologies that can be used for the estimation of replication fidelity.This study presents a number of product fingerprints,which propose multiple ways to characterize micro/nano structures in replication technologies.Replication fidelity yielded values above 80%and up to 96%depending on the considered product fingerprints and their definition.Thereafter,a correlation of the product fingerprint with the process parameters was found to optimize the replication process.Measurement uncertainty accompanies the analysis of the product fingerprints,enabling a standardized,robust,and quantitative methodology for process learning,modeling,and optimization.展开更多
This study explores the molding processes by using the Multi-component-injection molding (MCM) method, in which monolithic products are molded by attaching mixed liquid-silicone-rubbers (LSRs) to polybutylene terephth...This study explores the molding processes by using the Multi-component-injection molding (MCM) method, in which monolithic products are molded by attaching mixed liquid-silicone-rubbers (LSRs) to polybutylene terephthalate (PBT) that has the characteristic of self-binding while burning due to Pt catalysts. It is seen that this method increases the binding force between LSR and PBT. The surfaces coated with Polytetrafluoroethylene (PTFE), Cr, Ni, etc. have excellent peeling with plastic and such surfaces are compared with those treated with hot forging die and micro blasting without coating. When peeling tests are performed at the specified polymerization temperature and molding time after LSR molding on these surfaces of hot working die molds without coating, these surfaces show excellent peeling of molds and LSR products. In particular, they show better peeling after micro blasting than surfaces with Cr and Ni coating as well as surfaces without coating, and the peeling strength also decreases. The results of contact angle and XPS analysis indicate that the LSR binding force is enhanced as an effect of catalysts, though it is not found by SEM. According to the XPS analysis, the structures of the surfaces are close to methyl and vinyl materials that are produced while LSR molding.展开更多
基金Project supported by Development of Large Surface Micro-Machining System Technology of Ministry of Knowledge Economy, Korea
文摘A plastic plate with surface micro features was injection molded to investigate the effect of pressure rise of melt on the replication of the micro structures. Prism pattern, which is used in many optical applications, was selected as a model pattern. The prism pattern is 50 μm in pitch and 108° in the vertical angle. The overall size of the plate was 335 mm×213 mm and the thickness of the plate varied linearly from 2.6 mm to 0.7 mm. The prism pattern was firstly machined on the nickel plated core block using micro diamond tool and this machined pattern core was installed in a mold for injection molding of prism patterned plate. Polymethyl methacrylate (PMMA) was used as a molding material. The pressure and temperature of the melt in the cavity were measured at different positions in the cavity and the replication of the pattern was also measured at the same positions. The results show that the pressure or temperature profile through the process depends on the shape and the size of the plate. The replication is affected by the temperature and pressure profiles at the early stage of filling, which is right after the melt reaches the position to be measured.
基金Project(ZI648/13-1) supported by German Research FoundationProject(D/06/00373) supported by German Academic Exchange Service
文摘In order to reduce the "trial-mold" risk and cost,numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm(depth) ×0.4 mm(width) ×12 mm(length) in test area was selected as the objective part,and polypropylene(PP) as the experimental material. Respectively with specific commercial software(Mold Flow) and general computational fluid dynamic(CFD) software(Comsol Multiphysics) ,the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process,the specific commercial software for normal injection molding process is not valid to describe the micro flow process,the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle due to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development,the general CFD software,which is more flexible in user defining function,is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion,as for weld line forming process,the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process;but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.
基金supported by the National Natural Science Foundation of China (No. 51172018)the Fok Ying Tong Education Foundation (No.122016)
文摘Micro powder injection molding (μPIM) was investigated for possible mass production of micro-components at rela- tively low cost. However, scaling down to such a level produces challenges in injection molding and debinding. Micro gears were fabricated by μPIM from in-house feedstock. The effect of injection speed and injection pressure on the replication of the micro gear cavity was investigated. Solvent debinding and thermal debinding processes were discussed. The results show that micro gears can be successfully fabricated under the injection pressure of 70 MPa and the 60% injection speed. Either too low or too high injection speed can cause incomplete filling of micro gears. The same is the case with too low injection pressure. Too high injection pressure can bring cracks. Solvent debinding of micro gears was performed in a mixture of petroleum ether and ethanol. Subsequently, micro gears were successfully debound by a multistep heating schedule.
基金financially supported by the National Nature Science Foundation of China (Nos. 51102024 and 21276028)
文摘The ceramic injection molding technique was used in the gas-pressure sintering of ultra-fine Si3N4 powder. The feedstock's flowability, debinding rate, defect evolution, and microstructural evolution during production were explored. The results show that the solid volume loading of less than 50vol% and the surfactant mass fraction of 6wt% result in a perfect flowability of feedstock; this feedstock is suitable for injection molding. When the debinding time is 8 h at 40°C, approximately 50% of the wax can be solvent debinded. Defects detected during the preparation are traced to improper injection parameters, mold design, debinding parameters, residual stress, or inhomogeneous composition distribution in the green body. The bulk density, Vickers hardness, and fracture toughness of the gas-pressure-sintered Si3N4 ceramic reach 3.2 g/cm^3, 16.5 GPa, and 7.2 MPa·m^1/2, respectively.
基金Project supported by the National Natural Science Foundation of China(Nos.51303027 and 11172271)the Scientific Research Staring Foundation,Fujian University of Technology of China(No.GY-Z13028)+1 种基金the Research Fund of Fujian Education Department(No.JA11189)the Research Fund for Enterprise Technology Innovation(No.2011-702-04)
文摘In the micro-molding of component with a micro-sized channel, the ability for polymer melt to flowing into the micro-channel in a macro-sized part is a big challenge. The multidimensional flow behaviors are included in the injection molding the macro-component with a micro-channel. In this case, a simplified model is used to analyze the flow behaviors of the macro-sized part within a micro-channel. The flow behaviors in the macro-cavity are estimated by using the finite element and finite difference methods. The influence of the injection rate, micro-channel size, heat transfer coefficient, and mold temperature on the flowing distance is investigated based on the non-isothermal analytic method. The results show that an increase in the radius of the micro-channel and mold temperature can improve effectively the flowing distance in the micro-channel.
基金supported by a grant-in-aid for the National Core Research Center Program from the Ministry of Education Science & Technologythe Korea Science & Engineering Foundation (No.R15-2006-022-01001)
文摘Silicon carbide (SiC) is highly wear resistant with good mechanical properties, including high temperature strength, excellent chemical resistance, and high thermal conductivity and thermal shock resistance. SiC molds, which can be produced with diverse microstructural features, are now widely used in glass molding owing to their excellent characteristics, and also have potential applicability in IT industries. SiC molds are traditionally fabricated by silicon micromachining or dicing. The fabrication cost of silicon micromachining is very high, however, because several expensive masks are needed. Furthermore, the fabrication time is very long. Meanwhile, it is difficult to make micro-patterned molds with arbitrary shapes using dicing saws. Abrasive water jet (AWJ) is widely applied to cut and drill very brittle, soft and fibrous materials. It offers high energy density, the absence of a heat affected zone(HAZ), high performance, and an environment friendly process. In spite of these advantages, micro-hole drilling via conventional AWJ processing suffers from notable shortcomings. We proposed a new abrasive supplying method of AWJ. The proposed method reduces frosting phenomena, and provides micro-machining of AWJ. The characteristics of a hole machined was investigated by the proposed AWJ process according to the ratio of water and abrasives. With the optimal experimental conditions, 3×3 array SiC molds with the diameter of 700 μm and depth of 900 μm were successfully manufactured.
基金National Basic Research Program of China (Grant No. 2004CB719802)Hi-Tech Research and Development Program of China (Grant No. 2006AA03Z113)
文摘Micro powder injection molding (μPIM),a miniaturized variant of powder injection molding,has advantages of shape complexity,applicability to many materials and good mechanical properties. Co-injection molding has been realized between met-als and ceramics on micro components,which become the first breakthrough within the PIM field. Combined with the prominent characteristics of high features/cost ratio,micro powder injection molding becomes a potential technique for large scale production of intricate and three-dimensional micro components or micro-structured components in microsystems technology (MST) field.
基金The PROSURF project(“Surface Specifications and Process Chains for Functional Surfaces”,http://www.prosurf-project.eu/)is funded by the HORIZON 2020 program(Project ID:767589)the European Commission.MADE DIGITAL(Project ID:6151-00006B),Manufacturing Academy of Denmark(http://en.made.dk/),Work Package WP3“Digital manufacturing processes”,is funded by Innovation Fund Denmark(https://innovationsfonden.dk/en).
文摘Replication processes for the manufacturing of micro/nano-structured components are characterized by a certain degree of precision and accuracy.The transcription loss,or replication fidelity,defines the geometrical and dimensional correspondence of micro/nano-structure from metal tool inserts into plastic patterned products.The employment of a vast spectrum of micro/nano-structured geometries calls for methodologies that can be used for the estimation of replication fidelity.This study presents a number of product fingerprints,which propose multiple ways to characterize micro/nano structures in replication technologies.Replication fidelity yielded values above 80%and up to 96%depending on the considered product fingerprints and their definition.Thereafter,a correlation of the product fingerprint with the process parameters was found to optimize the replication process.Measurement uncertainty accompanies the analysis of the product fingerprints,enabling a standardized,robust,and quantitative methodology for process learning,modeling,and optimization.
文摘This study explores the molding processes by using the Multi-component-injection molding (MCM) method, in which monolithic products are molded by attaching mixed liquid-silicone-rubbers (LSRs) to polybutylene terephthalate (PBT) that has the characteristic of self-binding while burning due to Pt catalysts. It is seen that this method increases the binding force between LSR and PBT. The surfaces coated with Polytetrafluoroethylene (PTFE), Cr, Ni, etc. have excellent peeling with plastic and such surfaces are compared with those treated with hot forging die and micro blasting without coating. When peeling tests are performed at the specified polymerization temperature and molding time after LSR molding on these surfaces of hot working die molds without coating, these surfaces show excellent peeling of molds and LSR products. In particular, they show better peeling after micro blasting than surfaces with Cr and Ni coating as well as surfaces without coating, and the peeling strength also decreases. The results of contact angle and XPS analysis indicate that the LSR binding force is enhanced as an effect of catalysts, though it is not found by SEM. According to the XPS analysis, the structures of the surfaces are close to methyl and vinyl materials that are produced while LSR molding.