Experimental investigation and thermo-mechanical modelling for tool life evaluation of photopolymer additively manufactured mould inserts in different injection moulding conditions
- 102 Downloads
There is a growing interest for integrating additive manufacturing (AM) technology in different manufacturing processes such as injection moulding (IM) due to the possibility of achieving shorter manufacturing times and increased cost effectiveness. This paper evaluates IM inserts fabricated by the AM vat photopolymerisation method. The inserts are directly manufactured with a photopolymer material, integrated on an injection moulding tool and subsequently used for IM. Therefore, particular attention has to be paid in order to develop the soft tooling process chain and the IM experimental procedure as detailed in this study. Different combinations of IM parameters are investigated in this work in order to determine the influence of the various process settings on the inserts’ performance (lifetime, crack propagation, consistency of the mould surface features). The mould inserts were analysed by three-dimensional optical metrology and evaluated with regard to the different surface features that were affected by the IM process. A three-dimensional thermo-mechanical with phase change model for the analysis of the effects of the IM process on the additive manufactured tools was accomplished in the FE software COMSOL Multiphysics. The potential causes for the insert failure are identified both by means of the IM experiments and the numerical model. The developed model could also predict the thermally induced deformations produced in the mould and identify where this phenomenon would eventually lead to defects in the shape of the parts. The influence of three different temperatures of the insert at 25 °C, 50 °C and 100 °C on the failure of the insert was investigated. Also a detailed discussion about the solidification and temperature changes is given.
KeywordsAdditive manufacturing Vat photopolymerization Injection moulding Finite element modelling Soft tooling
Unable to display preview. Download preview PDF.
The research leading to these results has received funding from the People Programme (Marie Curie Actions) of the European Union’s Seventh Framework Programme (FP7/2007-2013) under REA grant agreement no. 609405 (COFUNDPostdocDTU).
- 2.Davoudinejad A, Ribo MM, Pedersen DB, Islam A, and Tosello G Direct fabrication of bio-inspired gecko-like geometries with vat polymerization additive manufacturing method. J Micromech Microeng 28(8). https://doi.org/10.1088/1361-6439/aabf17
- 4.Ovsianikov A, Malinauskas M, Schlie S, Chichkov B, Gittard S, Narayan R, Löbler M, Sternberg K, Schmitz KP, Haverich A (2011) Three-dimensional laser micro-and nano-structuring of acrylated poly (ethylene glycol) materials and evaluation of their cytoxicity for tissue engineering applications. Acta Biomater 7(3):967–974CrossRefGoogle Scholar
- 6.Lantada AD, Piotter V, Plewa K, Barié N, Guttmann M, Wissmann M (2014) Toward mass production of microtextured microdevices: linking rapid prototyping with microinjection molding. Int J Adv Manuf Technol 76(5–8):1011–1020Google Scholar
- 8.Mischkot M, Davoudinejad A, Charalambis A, Tosello G, Pedersen DB, Nørgaard H (2017) Dimensional accuracy of acrylonitrile butadiene styrene injection molded parts produced in a pilot production with an additively manufactured insert. In 33rd Conference of the Polymer Processing Society, at Cancun, MexicoGoogle Scholar
- 13.La M, Lee JG, Park SJ (2018) Numerical and experimental investigation of plastic injection molding of micro‐engineered surfaces. 58(S1) Special Issue: Thermoplastic Engineering. https://doi.org/10.1002/pen.24652
- 17.Technical datasheet, Acrylonitrile Butadiene Styrene (ABS)-Terluran® GP-35Google Scholar
- 21.Bergman TL, Incropera FP, DeWitt DP, Lavine AS (2011) Fundamentals of heat and mass transfer. John Wiley & SonsGoogle Scholar
- 23.Hattel JH, Pryds N, Thorborg J, Lipinski M, Schneider M, Hattel, JH (ed.) (2005) Fundamentals of Numerical Modelling of Casting Processes. Polyteknisk Forlag, DenmarkGoogle Scholar
- 24.Holman JP (2002) Heat transfer, 9th edn. McGraw-HillGoogle Scholar
- 25.Osswald Tim, Hernández-Ortiz JP (2006) Polymer processing. Modeling and Simulation.Google Scholar
- 27.Sadd MH (2009) Elasticity: theory, applications, and numerics. Academic PressGoogle Scholar
- 28.Budynas RG, Nisbett JK et al (2008) Shigley’s mechanical engineering design, vol 8. McGraw-Hill, New YorkGoogle Scholar