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Multi-Scale Simulation of Injection Molding Process with Micro-Features Replication: Relevance of Rheological

Sara Liparoti1, Vito Speranza1, Roberto Pantani1

  • 1Department of Industrial Engineering, University of Salerno, Via Giovanni Paolo II, 132, 84084 Fisciano, SA, Italy.

Polymers
|October 13, 2021
PubMed
Summary

Tailoring surface properties via injection molding enhances sustainability. A multiscale simulation approach accurately predicts micro/nanostructure replication, improving accuracy with higher cavity temperatures.

Keywords:
flow induced crystallizationmicro injection moldingmold temperature

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Area of Science:

  • Materials Science and Engineering
  • Polymer Processing
  • Computational Modeling

Background:

  • Injection molding allows tailoring surface properties for sustainability.
  • Surface properties depend on micro/nanostructure replication accuracy.
  • Accurate simulation of micro/nanostructure replication in injection molding is challenging.

Purpose of the Study:

  • To develop a multiscale simulation approach for injection molding with micro/nanostructures.
  • To improve the prediction of micro/nanostructure replication accuracy.
  • To investigate the influence of cavity temperature on surface property replication.

Main Methods:

  • A two-step multiscale simulation approach was employed.
  • Lubrication approximation and trapped air effects were incorporated.
  • A modified viscosity equation described isotactic polypropylene rheology at low temperatures.

Main Results:

  • The simulation accurately described polymer solidification during microcavity filling.
  • Replication accuracy of micro/nanostructures increased with cavity surface temperature.
  • The proposed methods align with experimental observations.

Conclusions:

  • The multiscale simulation approach effectively predicts micro/nanostructure replication in injection molding.
  • Cavity temperature is a critical factor for enhancing replication accuracy and surface properties.
  • This method contributes to sustainable manufacturing through improved process control.