Integrated process simulation of primary shaping: multi scale approaches

Abstract

We investigate simulation approaches for the modelling of the primary shaping processes micro powder injection moulding and micro casting. We could reproduce the segregation during micro powder injection moulding (MicroPIM) with a simulation using particle methods. The phase field method allows for accurate prediction of the dynamics of solidification of a melt, whereby model order reduction is used to limit the computational effort. The results give valuable advice for the process conduct and the dimensioning of the micro parts.

Micro metal injection molding (MicroMIM)

“…For the simulation of shear-induced powder segregation during injection, three important effects have to be considered: the migration of powder particles towards areas of lower concentration, which is caused by different collision frequencies; the migration of powder particles towards areas of lower shear rates; and the migration of powder particles towards areas of lower viscosities caused by viscosity inhomogeneities. After incorporating these approaches into the SPH model a correct prediction of powder distribution in MicroMIM parts was achieved as proven by computer tomography (CT) measurements using synchrotron radiation (Kauzlaric et al, 2008;Greiner et al, 2011). A similar objective, the creating of a PIM-specific simulation routine, is being pursued at the University of Besancon through the study of novel approaches, which are described in detail in Barriere et al (2003;2009) and Kong et al (2010).…”

New approaches in microcasting: permanent mold casting and composite casting

“…Additionally, the investigations on casting were accompanied by detailed research on the relationship of parameters, microstructure and mechanical properties (Baumeister et al 2008a, b;Auhorn et al 2002;Auhorn 2006;Kasanická et al 2005Kasanická et al , 2009Rögner et al 2011). Further, simulation of microcasting was added to gain deeper insights regarding form filling behavior and solidification (Kauzlaric et al 2008).…”

Constrained simulations of flow in haemodynamic devices: towards a computational assistance of magnetic resonance imaging measurements

“…However, only limited knowledge of the physics of these phenomena is available. Finally, the particles can be used to model each blood component by a discrete particle or, alternatively, a continuous concentration can be assigned to each fluid particle as an additional degree of freedom [17,18].…”