Experimental Validation of Injection Molding Simulations of 3D Microparts and Microstructured Components Using Virtual Design of Experiments and Multi-Scale Modeling
Experimental Validation of Injection Molding Simulations of 3D Microparts and Microstructured Components Using Virtual Design of Experiments and Multi-Scale Modeling
复制标题
基于虚拟实验设计和多尺度建模的三维微零件和微结构件注射成型模拟实验验证
DOI：
10.3390/mi11060614
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发表时间：
2020-06-01
期刊：
影响因子：
3.4
通讯作者：
Tosello, Guido
中科院分区：
文献类型：
--
作者：
Loaldi, Dario;Regi, Francesco;Tosello, Guido
对微注塑成型工艺技术和相应的微成型产品的需求不断增长，这体现在对模型和仿真能力的需求中，以建立制造过程的数字孪生模型。正确的工艺模拟所带来的机会包括预测零件质量和为给定产品找到最佳工艺条件的可能性。目前的工作显示进一步使用微注射成型过程模拟的特征尺寸的预测及其优化和微特征复制行为，由于几何边界效应。目前的工作重点是三维微型零件和具有微结构的单个组件的微注射成型。首先，进行了两个虚拟a研究，以预测10 μ m精度内的微环的外径和质量a为0.1 mg的微部件上的飞边形成。在第二部分的研究中，微观结构的取向上的微腔设计部分的填充时间的影响进行了研究的一个组件具有微槽与15 μ m的标称高度。采用多尺度网格法对菲涅耳透镜产品中17-346 μ m范围内的微特征的复制进行建模，从而能够以91%的精度预测微特征的复制行为。使用3D建模和广义Navier-Stokes方程，使用单一的多尺度模拟方法进行模拟。目前的工作表明，目前的潜力和限制，在使用微注射成型工艺模拟的微型3D零件和微结构部件的优化。
The increasing demand for micro-injection molding process technology and the corresponding micro-molded products have materialized in the need for models and simulation capabilities for the establishment of a digital twin of the manufacturing process. The opportunities enabled by the correct process simulation include the possibility of forecasting the part quality and finding optimal process conditions for a given product. The present work displays further use of micro-injection molding process simulation for the prediction of feature dimensions and its optimization and microfeature replication behavior due to geometrical boundary effects. The current work focused on the micro-injection molding of three-dimensional microparts and of single components featuring microstructures. First, two virtual a studies were performed to predict the outer diameter of a micro-ring within an accuracy of 10 mu m and the flash formation on a micro-component with mass a 0.1 mg. In the second part of the study, the influence of microstructure orientation on the filling time of a microcavity design section was investigated for a component featuring micro grooves with a 15 mu m nominal height. Multiscale meshing was employed to model the replication of microfeatures in a range of 17-346 mu m in a Fresnel lens product, allowing the prediction of the replication behavior of a microfeature at 91% accuracy. The simulations were performed using 3D modeling and generalized Navier-Stokes equations using a single multi-scale simulation approach. The current work shows the current potential and limitations in the use of micro-injection molding process simulations for the optimization of micro 3D-part and microstructured components.