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Title: Development of Metal/Polymer Mixtures Dedicated to Macro and Micro powder Injection Moulding : Experiments and Simulations

Abstract

Important research tasks at ENSMM/LMA are concerned for the development of mixtures of fine powders associated to polymer binders dedicated to the powder injection moulding (PIM) and to the powder injection micro-moulding ({mu}PIM) in accordance with many works already carried out with different feedstock suppliers dedicated to the macro-components. These research tasks are completed with the simulations of injection and sintering for solid state diffusion for to validate the mumerical models.

Authors:
; ;  [1]; ; ;  [2]
  1. FEMTO-ST Institute, Applied Mechanics Department, ENSMM, 26 rue de l'Epitaphe, 25000 Besancon (France)
  2. Department of Appl. Mech. and Eng., Southwest Jiaotong University, 610031 Chengdu, Sichuan (China)
Publication Date:
OSTI Identifier:
21057334
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM '07: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740957; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALLOYS; BINDERS; COMPOSITE MATERIALS; COMPUTERIZED SIMULATION; DIFFUSION; INJECTION; METALS; MIXTURES; MOLDING; NUMERICAL ANALYSIS; POLYMERS; POWDERS; SINTERING; SOLIDS

Citation Formats

Quinard, C., Barriere, T., Gelin, J. C., Song, J. P., Cheng, Z. Q., and Liu, B. S.. Development of Metal/Polymer Mixtures Dedicated to Macro and Micro powder Injection Moulding : Experiments and Simulations. United States: N. p., 2007. Web. doi:10.1063/1.2740957.
Quinard, C., Barriere, T., Gelin, J. C., Song, J. P., Cheng, Z. Q., & Liu, B. S.. Development of Metal/Polymer Mixtures Dedicated to Macro and Micro powder Injection Moulding : Experiments and Simulations. United States. doi:10.1063/1.2740957.
Quinard, C., Barriere, T., Gelin, J. C., Song, J. P., Cheng, Z. Q., and Liu, B. S.. Thu . "Development of Metal/Polymer Mixtures Dedicated to Macro and Micro powder Injection Moulding : Experiments and Simulations". United States. doi:10.1063/1.2740957.
@article{osti_21057334,
title = {Development of Metal/Polymer Mixtures Dedicated to Macro and Micro powder Injection Moulding : Experiments and Simulations},
author = {Quinard, C. and Barriere, T. and Gelin, J. C. and Song, J. P. and Cheng, Z. Q. and Liu, B. S.},
abstractNote = {Important research tasks at ENSMM/LMA are concerned for the development of mixtures of fine powders associated to polymer binders dedicated to the powder injection moulding (PIM) and to the powder injection micro-moulding ({mu}PIM) in accordance with many works already carried out with different feedstock suppliers dedicated to the macro-components. These research tasks are completed with the simulations of injection and sintering for solid state diffusion for to validate the mumerical models.},
doi = {10.1063/1.2740957},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}
  • Important research tasks at ENSMM/LMA are concerned for the development of mixtures of Fine powders associated to polymer binders dedicated to the powder injection moulding (PIM) and to the powder injection micro-moulding ({mu}PIM) in accordance with many works already carried out with different feedstock suppliers dedicated to the macro-components.
  • This paper presents different finite element simulations of thixoforging realised on Forge2(c) software. Compression and axial extrusion tests are particularly studied. The constitutive equation used for these simulations is based on a micro-macro approach accounting for the semi-solid microstructural evolution. The constitutive equation parameters are identified thanks to successive comparisons of the simulated load-displacement responses with experimental ones for compression tests on steel semi-solid at different temperatures. The relevance of the modelling is then analysed through extrusion tests. It is shown that the constitutive equation developed by the authors provides simulated results closer to the experimental ones than the classicalmore » Norton-Hoff law. It demonstrates the capacity of prediction of such a modelling. Moreover, these simulations give a lot of information concerning the role of parameters such as solid fraction, initial solid skeleton degree of agglomeration, thermal exchanges, or strain rate during thixoforging of high melting point materials.« less
  • A micro-macro algorithm for the calculation of polymer flow is developed and numerically evaluated. The system being solved consists of the momentum and mass conservation equations from continuum mechanics coupled with a microscopic-based rheological model for polymer stress. Standard finite element techniques are used to solve the conservation equations for velocity and pressure, while stochastic simulation techniques are used to compute polymer stress from the simulated polymer dynamics in the rheological model. The rheological model considered combines aspects of reptation, network and continuum models. Two types of spatial approximation are considered for the configuration fields defining the dynamics in themore » model: piecewise constant and piecewise linear. The micro-macro algorithm is evaluated by simulating the abrupt planar die entry flow of a polyisobutylene solution described in the literature. The computed velocity and stress fields are found to be essentially independent of mesh size and ensemble size, while there is some dependence of the results on the order of spatial approximation to the configuration fields close to the die entry. Comparison with experimental data shows that the piecewise linear approximation leads to better predictions of the centerline first normal stress difference. Finally, the computational time associated with the piecewise constant spatial approximation is found to be about 2.5 times lower than that associated with the piecewise linear approximation. This is the result of the more efficient time integration scheme that is possible with the former type of approximation due to the pointwise incompressibility guaranteed by the choice of velocity-pressure finite element.« less
  • Micro structured optical plastics components are intensively used i. e. in consumer electronics, for optical sensors in metrology, innovative LED-lighting or laser technology. Injection moulding has proven to be successful for the large-scale production of those parts. However, the production of those parts still causes difficulties due to challenges in the moulding and demoulding of plastics parts created with laser structured mould inserts. A complete moulding of the structures often leads to increased demoulding forces, which then cause a breaking of the structures and a clogging of the mould. An innovative approach is to combine PVD-coated (physical vapour deposition), lasermore » structured inserts and a variothermal moulding process to create functional mic8iüro structures in a one-step process. Therefore, a PVD-coating is applied after the laser structuring process in order to improve the wear resistance and the anti-adhesive properties against the plastics melt. In a series of moulding trials with polycarbonate (PC) and polymethylmethacrylate (PMMA) using different coated moulds, the mould temperature during injection was varied in the range of the glass transition and the melt temperature of the polymers. Subsequently, the surface topography of the moulded parts is evaluated by digital 3D laser-scanning microscopy. The influence of the moulding parameters and the coating of the mould insert on the moulding accuracy and the demoulding behaviour are being analysed. It is shown that micro structures created by ultra-short pulse laser ablation can be successfully replicated in a variothermal moulding process. Due to the mould coating, significant improvements could be achieved in producing micro structured optical plastics components.« less
  • This research used cement pastes with a low water/blaine ratio (W/b=0.27). Rice husk ashes (RHA) burned at 700 and 850 deg. C, silica fume, silica sand (Ottawa standard sand), etc., were the added ingredients. Wet-mixed steam injection (WMSI) was at five different temperatures: 65, 80, 120, 150 and 180 deg. C. We investigated cement pastes with added silica-rich materials. For different WMSI temperatures and times, we explored the relations between compressive strength, hydration products, and pozzolanic reaction mechanism. From scanning electron microscopy (SEM) and EDS, we know that hydration products become very complicated, depending on the WMSI temperatures and times.more » It is difficult to determine the direct effects on the strength based on changes in the products. Experimental results, however, clearly showed that the compressive strength was worst for 80 deg. C and best for 180 deg. C. High-temperature WMSI is best with 4-h presteaming period and 8-h retention time. Curing in saturated limewater for 28 days did not increase the strength. The three types of silica-rich materials used in this research all participated in the reaction during high-temperature WMSI; they helped to increase the strength. Addition of Ottawa standard sand resulted in the best strength, followed by addition of RHA, while addition of silica fume was worse than the others. Specimens treated with high-temperature WMSI would swell slightly if they were placed in air. This was different from normal-temperature curing.« less