Comprehensive characterization and material modeling for ceramic injection molding simulation performance validations

Guido Tosello*, David Maximilian Marhöfer, Aminul Islam, Tobias Müller, Klaus Plewa, Volker Piotter

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

Powder injection molding is like the process of plastics injection molding capable of the mass production of highly functional complex 3D parts, just in ceramics and metals. The market for productsmade by powder injection molding is constantly growing. With this growth, the need for reliable process simulations arises. Simulation tools are widely used in the development of new products and are applied in powder and polymer injection molding to support the product design, shorten the development time, avoid errors, and help to optimize the mold and process design. However, material data for feedstocks and thus simulations of the powder injection molding process are hardly available yet. The present work introduces the necessary material data for establishing a material model for simulations. An extensive material characterization of ceramic feedstocks was conducted. The material investigations comprised the determination of basic, thermal, and rheological material properties to collect a comprehensive data set. The necessary measurements and tools are outlined and their results are discussed in detailwith regard to powder content and in comparison to pure plastics. The gained data enabled to successfully create a material model for mold filling simulations. Powder injection molding experiments were carried out with a spiral test geometry. The mold was equipped with a sensor array for the process monitoring during injection. Furthermore, a simulation model of the test geometry was established. Finally, the results of the experiments and simulations are discussed and are compared to validate the performance of the simulations. The results showed the potential and limitations of process simulations and standard software applied in conventional and micro powder injection molding.
Original languageEnglish
JournalInternational Journal of Advanced Manufacturing Technology
Volume102
Pages (from-to)225-240
ISSN0268-3768
DOIs
Publication statusPublished - 2019

Keywords

  • Powder injection molding
  • Simulations
  • Feedstocks
  • Material characterization
  • Rheology

Cite this

@article{c8fcdc8c85bb495696c361b9a3382346,
title = "Comprehensive characterization and material modeling for ceramic injection molding simulation performance validations",
abstract = "Powder injection molding is like the process of plastics injection molding capable of the mass production of highly functional complex 3D parts, just in ceramics and metals. The market for productsmade by powder injection molding is constantly growing. With this growth, the need for reliable process simulations arises. Simulation tools are widely used in the development of new products and are applied in powder and polymer injection molding to support the product design, shorten the development time, avoid errors, and help to optimize the mold and process design. However, material data for feedstocks and thus simulations of the powder injection molding process are hardly available yet. The present work introduces the necessary material data for establishing a material model for simulations. An extensive material characterization of ceramic feedstocks was conducted. The material investigations comprised the determination of basic, thermal, and rheological material properties to collect a comprehensive data set. The necessary measurements and tools are outlined and their results are discussed in detailwith regard to powder content and in comparison to pure plastics. The gained data enabled to successfully create a material model for mold filling simulations. Powder injection molding experiments were carried out with a spiral test geometry. The mold was equipped with a sensor array for the process monitoring during injection. Furthermore, a simulation model of the test geometry was established. Finally, the results of the experiments and simulations are discussed and are compared to validate the performance of the simulations. The results showed the potential and limitations of process simulations and standard software applied in conventional and micro powder injection molding.",
keywords = "Powder injection molding, Simulations, Feedstocks, Material characterization, Rheology",
author = "Guido Tosello and Marh{\"o}fer, {David Maximilian} and Aminul Islam and Tobias M{\"u}ller and Klaus Plewa and Volker Piotter",
year = "2019",
doi = "10.1007/s00170-018-03251-3",
language = "English",
volume = "102",
pages = "225--240",
journal = "International Journal of Advanced Manufacturing Technology",
issn = "0268-3768",
publisher = "Springer U K",

}

Comprehensive characterization and material modeling for ceramic injection molding simulation performance validations. / Tosello, Guido; Marhöfer, David Maximilian; Islam, Aminul; Müller, Tobias; Plewa, Klaus; Piotter, Volker.

In: International Journal of Advanced Manufacturing Technology, Vol. 102, 2019, p. 225-240.

Research output: Contribution to journalJournal articleResearchpeer-review

TY - JOUR

T1 - Comprehensive characterization and material modeling for ceramic injection molding simulation performance validations

AU - Tosello, Guido

AU - Marhöfer, David Maximilian

AU - Islam, Aminul

AU - Müller, Tobias

AU - Plewa, Klaus

AU - Piotter, Volker

PY - 2019

Y1 - 2019

N2 - Powder injection molding is like the process of plastics injection molding capable of the mass production of highly functional complex 3D parts, just in ceramics and metals. The market for productsmade by powder injection molding is constantly growing. With this growth, the need for reliable process simulations arises. Simulation tools are widely used in the development of new products and are applied in powder and polymer injection molding to support the product design, shorten the development time, avoid errors, and help to optimize the mold and process design. However, material data for feedstocks and thus simulations of the powder injection molding process are hardly available yet. The present work introduces the necessary material data for establishing a material model for simulations. An extensive material characterization of ceramic feedstocks was conducted. The material investigations comprised the determination of basic, thermal, and rheological material properties to collect a comprehensive data set. The necessary measurements and tools are outlined and their results are discussed in detailwith regard to powder content and in comparison to pure plastics. The gained data enabled to successfully create a material model for mold filling simulations. Powder injection molding experiments were carried out with a spiral test geometry. The mold was equipped with a sensor array for the process monitoring during injection. Furthermore, a simulation model of the test geometry was established. Finally, the results of the experiments and simulations are discussed and are compared to validate the performance of the simulations. The results showed the potential and limitations of process simulations and standard software applied in conventional and micro powder injection molding.

AB - Powder injection molding is like the process of plastics injection molding capable of the mass production of highly functional complex 3D parts, just in ceramics and metals. The market for productsmade by powder injection molding is constantly growing. With this growth, the need for reliable process simulations arises. Simulation tools are widely used in the development of new products and are applied in powder and polymer injection molding to support the product design, shorten the development time, avoid errors, and help to optimize the mold and process design. However, material data for feedstocks and thus simulations of the powder injection molding process are hardly available yet. The present work introduces the necessary material data for establishing a material model for simulations. An extensive material characterization of ceramic feedstocks was conducted. The material investigations comprised the determination of basic, thermal, and rheological material properties to collect a comprehensive data set. The necessary measurements and tools are outlined and their results are discussed in detailwith regard to powder content and in comparison to pure plastics. The gained data enabled to successfully create a material model for mold filling simulations. Powder injection molding experiments were carried out with a spiral test geometry. The mold was equipped with a sensor array for the process monitoring during injection. Furthermore, a simulation model of the test geometry was established. Finally, the results of the experiments and simulations are discussed and are compared to validate the performance of the simulations. The results showed the potential and limitations of process simulations and standard software applied in conventional and micro powder injection molding.

KW - Powder injection molding

KW - Simulations

KW - Feedstocks

KW - Material characterization

KW - Rheology

U2 - 10.1007/s00170-018-03251-3

DO - 10.1007/s00170-018-03251-3

M3 - Journal article

VL - 102

SP - 225

EP - 240

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

ER -