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Finite Element Method application for structure determining of powder injection moulding samples

Śliwa A., Matula M., Dobrzański L.A.

Archives of Computational Materials Science and Surface Engineering

2010

Vol. 2, nr 3

157-164

Purpose: To improve the understanding of the rheology of a metal-loaded polymer, a computer program which simulates the powder injection molding (PIM) process has been developed and its output has been compared to actual laboratory experiments. Design/methodology/approach: The polymer-powder feedstock was injection moulded using Arburg injection moulding machine. Feedstock of M2 HSS reinforced with carbides and mixed with stearic acid, paraffin wax and polypropylene as a binder was made by twin-screw extruder. Feedstock viscosity examination was made by capillary rheometer HAAKE RheoCap. Computer simulation results were compared with experimental results. Findings: Computer aided numerical analysis gives the possibility to select the optimal parameters of injection moulding without necessitate of preparation different feedstocks and manufacturing injected samples in different conditions of injection. Moreover application of ANSYS allows to apply initial process of injection moulding simulations without the necessity of purchasing expensive programs applied to material modeling injection. Research limitations/implications: It was confirmed that using of finite element method in powder injection moulding process can be a way for reducing the investigation costs Results reached in this way are satisfying and in slight degree differ from results reached by experimental method. However for achieving better calculation accuracy in further researches it should be developed given model which was presented in this paper. Originality/value: Nowadays the computer simulation is very popular and it is based on the finite element method, which allows to better understand the interdependence between parameters of process and choosing optimal solution. The possibility of application faster and faster calculation machines and coming into being many software make possible the creation of more precise models and more adequate ones to reality.