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Injection Molding Simulation: New State of the Art for Micromolding Applications and Nano-Composites

4/11/2012

The adjustment of the solver technology from SIGMASOFT® to the micromolding scale makes it possible to accurately predict the injection molding process also for micro-scale molding applications. The rheological models used by the software were extended, so that the influence of nanoparticles over the rheological behavior can be considered and the distribution of the nanoparticles over the plastic melt can be predicted.

Figure 1 - Visualization in SIGMASOFT® of the particle concentration over the length of an injection molded micro-specimen for tensile testing.

Schaumburg, IL, April 1st 2012 - SIGMA Plastic Services, Inc., Schaumburg, IL, presents the latest expansions in the functionality of its 3D injection simulation software SIGMASOFT®. A focus of the latest developments is the simulation of micro-molded applications and the integration of nano-composites.

Nano-composites influence the rheology of plastic melts significantly. By improving the melt fluidity, processing at lower temperatures is possible, saving energy and cycle time. Furthermore, the part properties can be tailored by using nanoparticles as reinforcement. However, these advantages can only be reached if the nanoparticles achieve the desired distribution in the cavity and if no particle-segregation occurs as a consequence of flow effects.

The nanoparticle distribution should be considered early, during part and mold design, and measures should be taken to avoid undesirable results. Therefore, a new model was integrated into the injection molding simulation software SIGMASOFT®, which now makes it possible to simulate and analyze the local particle distribution and thus define clear guidelines for the design of part, mold and runner system.
An interesting field of application for nano-scale particles is the property modification in micromolding applications. Due to the significant variation in proportions between the size of the part and the size of the mold, micro-injection molding exhibits particular thermo-rheological effects, which are ignored in the conventional modeling available for the injection molding simulation of macro-applications. Particularly, the thermal interaction between mold and melt on the nano-scale must be considered and defined exactly from the physical point of view. The solver technology of SIGMASOFT® was extended and validated to consider these nano-scale-induced effects.

The results were obtained as part of the German BMBF research project "Process Development for the injection Molding of Nano-composites for the serial production of micro- and macro-applications". Also the companies Doose Werkzeugbau (Hennstedt-Ulzburg), Krämer Engineering (Rendsburg), WISKA Hoppmann & Mulsow GmbH (Kaltenkirchen), JENOPTIK Polymer Systems GmbH (Triptis) and the Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM, (Bremen) collaborated on this research project.

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