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3 Journal of Achievements in Materials and Manufacturing Engineering

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Simulation of powder injection moulding conditions using cadmould program

100%

Matula G. , Dobrzański L. A. , Ambroziak M.

2012

tom Vol. 55, nr 2

556--560

Purpose: Development of a new generation tool materials on the basis of high speed-steel manufactured by Powder Injection Moulding. To investigate formability of the polymer-powder slurry in which the HS12-1-5-5 (T15) high-speed steel powder was used, as well as the HD-PE polyethylene and paraffin, the „Cadmould” commercial software was employed, developed mostly for simulation of the powder injection moulding of the thermoplastic and composites. Design/methodology/approach: Powder metallurgy, powder injection moulding, sintering, microstructure examination, symulation of injection moulding. Findings: Simulation of powder injection moulding was preceded by the rheological tests, which made obtaining possible of the data indispensable for modelling, pertaining to the polymer-powder slurry viscosity. The portion of particles reinforcing the composite is usually lower than powder portion in mixtures used for forming and next binding agent degradation and sintering. The big powder portion is often the reason for the high viscosity of the mixture and problems with its forming. However, simulation results revealed that the fabricated polymer-powder mixture may be injected, which was confirmed by carrying out powder injection moulding on a typical Arburg injection moulding machine using in the industry. Practical implications: Application of powder injection moulding to manufacturing of high speed steel matrix composites gives the possibility to obtain tool materials with the relative high ductility characteristic of steel and high hardness and wear resistance typical for cemented carbides. Originality/value: Application of symulation of powder injection moulding conditions using cadmould program gives the possibility to reduce cost of expensive injection mould and control the injection conditions.

Finite Element Method application during powder injection moulding

63%

Śliwa A. , Matula M. , Dobrzański L. A.

2009

tom Vol. 37, nr 2

584-591

Purpose: The general topic of this paper is problem of model ling of a polymer-powder mix flow during filling, in which the high-speed steel was used along with paraffin and polypropylene as a binding agent. Design/methodology/approach: Modelling of the polymer-powder mix flow process during filling was performed using the finite element method in Cadmould environment; polymer-powder mix was injection moulded using Arburg injection moulder. Computer simulation results were compared with experimental results. Findings: The presented model meets the initial criteria, which gives ground to the assumption about its usability for injection moulding of polymer-powder slurry process, employing the finite element method using the Cadmould software. The computer simulation results correlate with the experimental results. 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

Application of powder injection moulding for manufacturing of tool composite materials

63%

Matula G. , Jędrzejewska-Anioł A. , Niespodziański J.

2013

tom Vol. 59, nr 2

80--85

Purpose: The goal of this work is development of the tool composites on the basis of T15 HSS contained 10% of carbides. This tool material were manufactured by Powder Injection Moulding method and sintered. Design/methodology/approach: Torque-load test, rheological tests, thermal debinding, sintering, hardness test and microstructure examinations. Findings: Examination of the effect of the binder type and portion on structure and properties of the experimental tool materials revealed that using the stearic acid for covering the carbides surface reduces viscosity, thus improving technological properties of the feedstock. Employment of polypropylene instead of the high density polyethylene reduces viscosity and torque-load of the investigated feedstocks. Therefore, there is a possibility to increase the portion of the metallic and ceramic powder. Practical implications: Stearic acid significantly reduces the viscosity of tested polymer-powder mixtures, so its use is justified. The share of the binder in materials, injection molded or extruded should be minimal and allows only the formation of the slurry. Too high proportion of binder creates difficulties during the degradation and causes greater shrinkage and possibility of a distortion during sintering. Employment of polyethylene instead of the high density polypropylene reduces viscosity and torque-load of the investigated feedstocks. Therefore, there is a possibility to increase the portion of the metallic or ceramic powder. This results in a lower deformation probability and in a lower sinter shrinkage. Originality/value: In the paper the using extruding of the polymer-powder mix gives the possibility to fabricate cermets which, with their structure and mechanical properties, fill the gap in tool materials between the high-speed steels and cemented carbides.