Experimental investigation and thermo-mechanical modelling for tool life evaluation of photopolymer additively manufactured mould inserts in different injection moulding conditions

Ali Davoudinejad*, Mohamad Bayat, David Bue Pedersen, Yang Zhang, Jesper Henri Hattel, Guido Tosello

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

There is a growing interest for integrating additive manufacturing (AM) technology in different manufacturing processes such as injection moulding (IM) due to the possibility of achieving shorter manufacturing times and increased cost effectiveness. This paper evaluates IM inserts fabricated by the AM vat photopolymerisation method. The inserts are directly manufactured with a photopolymer material, integrated on an injection moulding tool and subsequently used for IM. Therefore, particular attention has to be paid in order to develop the soft tooling process chain and the IM experimental procedure as detailed in this study. Different combinations of IM parameters are investigated in this work in order to determine the influence of the various process settings on the inserts’ performance (lifetime, crack propagation, consistency of the mould surface features). The mould inserts were analysed by three-dimensional optical metrology and evaluated with regard to the different surface features that were affected by the IM process. A three-dimensional thermo-mechanical with phase change model for the analysis of the effects of the IM process on the additive manufactured tools was accomplished in the FE software COMSOL Multiphysics. The potential causes for the insert failure are identified both by means of the IM experiments and the numerical model. The developed model could also predict the thermally induced deformations produced in the mould and identify where this phenomenon would eventually lead to defects in the shape of the parts. The influence of three different temperatures of the insert at 25 °C, 50 °C and 100 °C on the failure of the insert was investigated. Also a detailed discussion about the solidification and temperature changes is given.
Original languageEnglish
JournalInternational Journal of Advanced Manufacturing Technology
Volume102
Issue number1-4
Pages (from-to)403–420
ISSN1433-3015
DOIs
Publication statusPublished - 2019

Keywords

  • Additive manufacturing
  • Vat photopolymerization
  • Injection moulding
  • Finite element modelling
  • Soft tooling

Cite this

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title = "Experimental investigation and thermo-mechanical modelling for tool life evaluation of photopolymer additively manufactured mould inserts in different injection moulding conditions",
abstract = "There is a growing interest for integrating additive manufacturing (AM) technology in different manufacturing processes such as injection moulding (IM) due to the possibility of achieving shorter manufacturing times and increased cost effectiveness. This paper evaluates IM inserts fabricated by the AM vat photopolymerisation method. The inserts are directly manufactured with a photopolymer material, integrated on an injection moulding tool and subsequently used for IM. Therefore, particular attention has to be paid in order to develop the soft tooling process chain and the IM experimental procedure as detailed in this study. Different combinations of IM parameters are investigated in this work in order to determine the influence of the various process settings on the inserts’ performance (lifetime, crack propagation, consistency of the mould surface features). The mould inserts were analysed by three-dimensional optical metrology and evaluated with regard to the different surface features that were affected by the IM process. A three-dimensional thermo-mechanical with phase change model for the analysis of the effects of the IM process on the additive manufactured tools was accomplished in the FE software COMSOL Multiphysics. The potential causes for the insert failure are identified both by means of the IM experiments and the numerical model. The developed model could also predict the thermally induced deformations produced in the mould and identify where this phenomenon would eventually lead to defects in the shape of the parts. The influence of three different temperatures of the insert at 25 °C, 50 °C and 100 °C on the failure of the insert was investigated. Also a detailed discussion about the solidification and temperature changes is given.",
keywords = "Additive manufacturing, Vat photopolymerization, Injection moulding, Finite element modelling, Soft tooling",
author = "Ali Davoudinejad and Mohamad Bayat and Pedersen, {David Bue} and Yang Zhang and Hattel, {Jesper Henri} and Guido Tosello",
year = "2019",
doi = "10.1007/s00170-018-3163-7",
language = "English",
volume = "102",
pages = "403–420",
journal = "International Journal of Advanced Manufacturing Technology",
issn = "0268-3768",
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T1 - Experimental investigation and thermo-mechanical modelling for tool life evaluation of photopolymer additively manufactured mould inserts in different injection moulding conditions

AU - Davoudinejad, Ali

AU - Bayat, Mohamad

AU - Pedersen, David Bue

AU - Zhang, Yang

AU - Hattel, Jesper Henri

AU - Tosello, Guido

PY - 2019

Y1 - 2019

N2 - There is a growing interest for integrating additive manufacturing (AM) technology in different manufacturing processes such as injection moulding (IM) due to the possibility of achieving shorter manufacturing times and increased cost effectiveness. This paper evaluates IM inserts fabricated by the AM vat photopolymerisation method. The inserts are directly manufactured with a photopolymer material, integrated on an injection moulding tool and subsequently used for IM. Therefore, particular attention has to be paid in order to develop the soft tooling process chain and the IM experimental procedure as detailed in this study. Different combinations of IM parameters are investigated in this work in order to determine the influence of the various process settings on the inserts’ performance (lifetime, crack propagation, consistency of the mould surface features). The mould inserts were analysed by three-dimensional optical metrology and evaluated with regard to the different surface features that were affected by the IM process. A three-dimensional thermo-mechanical with phase change model for the analysis of the effects of the IM process on the additive manufactured tools was accomplished in the FE software COMSOL Multiphysics. The potential causes for the insert failure are identified both by means of the IM experiments and the numerical model. The developed model could also predict the thermally induced deformations produced in the mould and identify where this phenomenon would eventually lead to defects in the shape of the parts. The influence of three different temperatures of the insert at 25 °C, 50 °C and 100 °C on the failure of the insert was investigated. Also a detailed discussion about the solidification and temperature changes is given.

AB - There is a growing interest for integrating additive manufacturing (AM) technology in different manufacturing processes such as injection moulding (IM) due to the possibility of achieving shorter manufacturing times and increased cost effectiveness. This paper evaluates IM inserts fabricated by the AM vat photopolymerisation method. The inserts are directly manufactured with a photopolymer material, integrated on an injection moulding tool and subsequently used for IM. Therefore, particular attention has to be paid in order to develop the soft tooling process chain and the IM experimental procedure as detailed in this study. Different combinations of IM parameters are investigated in this work in order to determine the influence of the various process settings on the inserts’ performance (lifetime, crack propagation, consistency of the mould surface features). The mould inserts were analysed by three-dimensional optical metrology and evaluated with regard to the different surface features that were affected by the IM process. A three-dimensional thermo-mechanical with phase change model for the analysis of the effects of the IM process on the additive manufactured tools was accomplished in the FE software COMSOL Multiphysics. The potential causes for the insert failure are identified both by means of the IM experiments and the numerical model. The developed model could also predict the thermally induced deformations produced in the mould and identify where this phenomenon would eventually lead to defects in the shape of the parts. The influence of three different temperatures of the insert at 25 °C, 50 °C and 100 °C on the failure of the insert was investigated. Also a detailed discussion about the solidification and temperature changes is given.

KW - Additive manufacturing

KW - Vat photopolymerization

KW - Injection moulding

KW - Finite element modelling

KW - Soft tooling

U2 - 10.1007/s00170-018-3163-7

DO - 10.1007/s00170-018-3163-7

M3 - Journal article

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EP - 420

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

IS - 1-4

ER -