A novel method for determining the pressure dependent characteristics of polymer melt during micro injection molding

IF 6 2区材料科学 Q1 MATERIALS SCIENCE, CHARACTERIZATION & TESTING Polymer Testing Pub Date : 2024-08-01 Epub Date: 2024-07-15 DOI:10.1016/j.polymertesting.2024.108520

Junjie Liu , Baishun Zhao , Dimitrios Kontziampasis , Bingyan Jiang , Wangqing Wu

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Abstract

Micro injection molding is used to manufacture thin-walled parts with micron-scale structures. wherein high shear rate and high injection pressure process conditions appear. Consequently, the pressure dependence of polymer melt viscosity at the microscale cannot be ignored. However, in the simulation analysis of the microinjection molding process, almost all the Cross-WLF models of polymeric materials are omitting the pressure dependence parameter D₃. This has a huge impact on the accuracy of the simulation results. Herein, a method that combines experimental characterization and filling simulation is proposed for the determination of the pressure dependence of polymer melts during micro injection molding. D₃ in the Cross-WLF model of Polymethyl methacrylate (PMMA) and Cycloolefin copolymer (COC) is characterized by capillary rheometer and counter pressure chamber. The developed viscosity model including D₃ is used for a filling simulation and is compared with the experimental results. The model flow simulation results showcases that the prediction accuracy of the viscosity model is significantly improved after considering D₃. These results are of great significance, as they can be used to reduce the development cost and to improve the simulation accuracy of the micro injection molding filling process.

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确定微注塑成型过程中聚合物熔体压力相关特性的新方法

微注塑成型用于制造具有微米级结构的薄壁部件，其中出现了高剪切速率和高注塑压力的工艺条件。因此，微尺度下聚合物熔体粘度的压力依赖性不容忽视。然而，在微注塑过程的模拟分析中，几乎所有聚合物材料的 Cross-WLF 模型都忽略了压力相关参数 D3。这对模拟结果的准确性有很大影响。本文提出了一种结合实验表征和填充模拟的方法，用于确定聚合物熔体在微注塑过程中的压力依赖性。利用毛细管流变仪和反压室对聚甲基丙烯酸甲酯（PMMA）和环烯烃共聚物（COC）的 Cross-WLF 模型中的 D3 进行了表征。开发的粘度模型（包括 D3）被用于填充模拟，并与实验结果进行了比较。模型流动模拟结果表明，在考虑了 D3 后，粘度模型的预测精度有了显著提高。这些结果可用于降低开发成本和提高微注塑填充过程的模拟精度，因此具有重要意义。

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来源期刊

Polymer Testing 工程技术-材料科学：表征与测试

CiteScore

10.70

自引率

5.90%

发文量

328

审稿时长

44 days

期刊介绍： Polymer Testing focuses on the testing, analysis and characterization of polymer materials, including both synthetic and natural or biobased polymers. Novel testing methods and the testing of novel polymeric materials in bulk, solution and dispersion is covered. In addition, we welcome the submission of the testing of polymeric materials for a wide range of applications and industrial products as well as nanoscale characterization. The scope includes but is not limited to the following main topics: Novel testing methods and Chemical analysis • mechanical, thermal, electrical, chemical, imaging, spectroscopy, scattering and rheology Physical properties and behaviour of novel polymer systems • nanoscale properties, morphology, transport properties Degradation and recycling of polymeric materials when combined with novel testing or characterization methods • degradation, biodegradation, ageing and fire retardancy Modelling and Simulation work will be only considered when it is linked to new or previously published experimental results.