Analysis of a hybrid process for manufacturing sheet metal-polymer structures using a conceptual tool design and an analytical-numerical modelling
Analysis of a hybrid process for manufacturing sheet metal-polymer structures using a conceptual tool design and an analytical-numerical modelling
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DOI：
10.1016/j.jmatprotec.2019.116533
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发表时间：
2020-05-01
影响因子：
6.3
通讯作者：
Pilla, Srikanth
中科院分区：
文献类型：
--
作者：
Farahani, Saeed;Yerra, Veera Aditya;Pilla, Srikanth
本文对聚合物注射成形（PIF）的混合过程进行了实验和数值研究，该混合过程是为一次性制造金属板材-聚合物结构而开发的。尽管PIF工艺具有广泛的应用潜力，但一些挑战阻碍了对这种混合工艺中同时发生的注射/成型条件进行深入分析。一个这样的挑战是缺乏一个特殊的功能，在常规注塑机独立应用和控制压边力（BHF）从预设夹紧力。为此，本文提出了一种新的从概念到设计的工具。利用这种专门的装置，通过实验确定了压边力、注射速度及其相互作用的影响，重点研究了瞬态PIF过程变量和最终混合产品的质量。使用流固相互作用（SFI）方法对PIF过程进行多物理场模拟会产生很大的计算成本，因此进行多次模拟来研究多个过程参数及其相互作用的影响是不合理的。为了达到效率和准确性，提出了一种新的结合分析和数值的方法，以便考虑填充、拉伸和拉伸机制的相互作用，对PIF过程物理进行基本的理解。通过对a1100板材在不同注射速度和压边力条件下注射聚丙烯复合材料时的变形进行对比分析，验证了所提出的数值方法和实验方法的可行性。
This paper presents an experimental and numerical study on the hybrid process of polymer injection forming (PIF) developed to manufacture sheet metal-polymer structures in one single operation. Despite the wide potential application of the PIF process, several challenges have prevented conducting an in-depth analysis of the simultaneous injection/forming condition that occurs during this hybrid process. One such challenge is the lack of a special feature in the regular injection molding machine for an independent application and control of the blank holder force (BHF) from the preset clamping force. To enable such, a new concept-to-design tool is proposed in this work. Using this specialized setup, the influence of the BHF, injection rate and their interactions are experimentally determined focusing on the transient PIF process variables and the quality of the final hybrid product. The use of the fluid-structure interaction (SFI) method to perform a multi-physics simulation on the PIF process incurs such computational costs that it is unreasonable to conduct multiple simulations to investigate the effects of several process parameters and their interactions. To achieve both efficiency and accuracy, a new combined analytical-numerical approach is presented to enable fundamental understanding of the PIF process physics considering the interaction of filling, stretching and drawing mechanisms. The feasibility of the proposed numerical and experimental methodologies is demonstrated through a comparative analysis of the deformation of the AA1100 sheet during the injection of a Polypropylene compound with different injection rates and BHF settings.