Optimization of the morphological multi-layer system of micro components by means of a thermally highly flexible process strategy

内部组分性质实质上影响了半结晶热塑性塑料中组分的最终性质。部件内部性能的发展主要取决于部件的冷却条件。这些冷却条件取决于模具温度，因为组件的最小厚度，特别是关于微组件。由于缺乏对选定的回火参数、内部性能的建立和由此产生的摩擦学性能之间的因果关系的了解，摩擦学上最优的微部件的开发受到了限制。在“加工诱导的形态对热塑性微齿轮性能的影响”研究项目中，能够获得有关内部部件性能对最终摩擦学性能影响的基本信息。结果表明，最佳的摩擦学特性表现在部件内部具有独特的内部部件特性的特定区域。通过传统的动态温度策略，使冷却在几乎恒定的冷却速率，沿组件边缘实现更高的冷却速度。因此，出现了较少的明显的内部成分性能和不利的摩擦学性能。虽然较慢的冷却速度可以带来更好的摩擦学性能，但它会导致更长的循环时间。为了减少循环时间和达到最佳的摩擦学性能，需要灵活调节模具系统的冷却速度。然而，目前的技术已经证明这是不够的。本转移项目的目的是研究上述微注射成型中的冷却条件，以确保热塑性部件截面的每一有限层都暴露在结晶温度区域。此外，通过过程模拟生成理想的、理论上的注射成型温度分布是至关重要的。最终目标是有针对性地控制模具温度，以优化内部组件性能，同时，通过新的，高度动态的模具回火策略最小化周期时间。利用迄今为止获得的知识，将制造一个演示器，这里是一个微型齿轮，在整个横截面上具有均匀，定义和最佳的组件特性。在获得的结果的帮助下，探索新的基本问题成为可能。利用最新的表征方法分析结晶行为与基于工艺的冷却条件，可以建立一个过程仿真模型，其中可以理想地考虑微注射成型的要求。此外，还可以考虑用非晶和耐高温材料制造微型元件的能力。

Inner componential properties substantially affect the components resulting properties within semi-crystalline thermoplastics. How inner-componential properties develop primarily depends on the cooling conditions of the component. These cooling conditions depend on the mold temperature due to the components minimal thickness, especially with regards to micro components. Due to a lack of knowledge on the causal relationships between selected tempering parameters, the establishment of inner properties and the resulting tribological properties, the development of tribologically optimal micro components has proven limited. In the research project "Processing induced morphological influences on the properties of thermoplastic micro gears" fundamental information regarding the influence of inner component properties on the resulting tribological properties were able to be obtained. Results showed that optimal tribological characteristics manifest in particular regions within the component with distinct, inner componential properties. By means of a conventional dynamic temperature strategy, which enables cooling at nearly constant cooling rates, higher cooling velocities along the components edges are achieved. Consequently, fewer distinct, inner componential properties and unfavorable tribological properties are emerged. While slower cooling rates could lead to better tribological properties, it would cause significantly longer cycle time. In order to reduce cycle times and to achieve optimal tribological properties, the mold systems cooling velocity needs to be adjustable flexibly. However, this has proven to be inadequate with current techniques. The aim of this transfer project is to study the aforementioned cooling conditions in micro injection molding, which ensure that every finite layer of a thermoplastic components cross section is exposed to the crystallization temperature area. Additionally, generating an idealized, theoretical injection molding temperature profile through process simulation is of fundamental importance. The ultimate aim is a targeted control of the mold temperature in order to optimize the inner-componential properties and, simultaneously, minimize the cycle time with a new, highly dynamic mold tempering strategy. Using the knowledge acquired to date, a demonstrator, here a micro gear, with homogenous, defined and optimal componential properties across the entire cross-section will be manufactured. With the help of obtained results, exploring new, fundamental questions becomes possible. Using the latest characterization methods for analyzing crystallization behavior with process-based cooling conditions allows establishing a process simulation model in which the micro-injection molding requirements can be ideally considered. Furthermore, the ability to manufacture micro-components with amorphous and highly temperature-resistant materials could also be considered.