Investigating demoulding characteristics of material jetted rapid mould inserts for micro­injection moulding using in­line monitoring and surface metrology

Mert Gülçür, Dmitry Isakov, Jérôme Charmet, Gregory J. Gibbons
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Abstract

Purpose This study aims to investigate the demoulding characteristics of material-jetted rapid mould inserts having different surface textures for micro-injection moulding using in-line measurements and surface metrology. Design/methodology/approach Material-jetted inserts with the negative cavity of a circular test product were fabricated using different surface finishes and printing configurations, including glossy, matte and vertical settings. In-line measurements included the recording of demoulding forces at 10 kHz, which was necessary to capture the highly-dynamic characteristics. A robust data processing algorithm was used to extract reliable demoulding energies per moulding run. Thermal imaging captured surface temperatures on the inserts after demoulding. Off-line measurements, including focus variation microscopy and scanning electron microscopy, compared surface textures after a total of 60 moulding runs. Findings A framework for capturing demoulding energies from material-jetted rapid tools was demonstrated and compared to the literature. Glossy surfaces resulted in significantly reduced demoulding forces compared to the industry standard steel moulds in the literature and their material-jetted counterparts. Minimal changes in the surface textures of the material-jetted inserts were found, which could potentially permit their prolonged usage. Significant correlations between surface temperatures and demoulding energies were demonstrated. Originality/value The research presented here addresses the very topical issue of demoulding characteristics of soft, rapid tools, which affect the quality of prototyped products and tool durability. This was done using state-of-the-art, high-speed sensing technologies in conjunction with surface metrology and their durability for the first time in the literature.
利用在线监测和表面计量研究用于微注塑成型的材料喷射快速模具镶件的脱模特性
本研究旨在利用在线测量和表面计量学方法,研究具有不同表面纹理的材料喷射快速模具镶件的脱模特性,这些镶件用于微注塑成型。在线测量包括以 10 kHz 频率记录脱模力,这对于捕捉高动态特性非常必要。我们采用了强大的数据处理算法,以提取每次注塑运行的可靠脱模能量。热成像技术捕捉了脱模后镶件的表面温度。离线测量(包括聚焦变化显微镜和扫描电子显微镜)比较了总共 60 次造型运行后的表面纹理。与文献中的工业标准钢模及其材料喷射的同类产品相比,光亮表面显著降低了脱模力。研究发现,材料喷射镶件的表面纹理变化极小,因此可以长期使用。研究表明,表面温度与脱模能量之间存在显著的相关性。 原创性/价值本文介绍的研究解决了软质快速工具脱模特性这一非常热门的问题,该特性会影响原型产品的质量和工具的耐用性。这项研究采用了最先进的高速传感技术,并结合了表面计量及其耐用性,这在文献中尚属首次。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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