Ultrasonic plasticizing micro-injection molding of UHMWPE based on new process flow and ultrasonic system structure to improve mechanical properties and process stability

IF 8.7 1区化学 Q1 ACOUSTICS

Ultrasonics Sonochemistry Pub Date : 2025-02-12 DOI:10.1016/j.ultsonch.2025.107272

Zhiying Shan , Xingbo Qin , Hang Li , Yanghui Xiang , Wangqing Wu

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引用次数: 0

Abstract

Ultrasonic plasticizing micro-injection molding (UPMIM) technology has been considered as an effective means of UHMWPE molding. However, the cumbersome forming process, the degradation of mechanical properties and the poor consistency of molding and property seriously restrict further application. In this study, a new ultrasonic molding method of UHMWPE micro-parts is proposed. Firstly, the UHMWPE ultrasonic plasticizing material was prepared simply and quickly by ultrasonic technology. Secondly, the UHMWPE tensile samples were molded by an innovative UPMIM structure with a large diameter ratio of the ultrasonic sonotrode to plasticizing cavity. Then, the optimum molding process parameters were obtained by grey relational analysis (GRA). After that, the influence of system stability and process parameters on mechanical properties and consistency was studied by contribution analysis. Finally, compared with the typical UHMWPE molding method (compression molding) and the existing research results, the influence and feasibility of the process are analyzed in detail. The results show that the ultrasonic technique can effectively prepare UHMWPE tablets with almost unchanged properties (molecular weight decreased by 0.31 %). A large diameter ratio of the ultrasonic sonotrode to plasticizing cavity can expand the process window for complete filling of UHMWPE tensile samples, and the filling stability of the ultrasonic system is increased by about 1.8 times. Meanwhile, this ultrasonic system structure can also inhibit the oxidative degradation of UHMWPE, reduce the break of molecular chain. The elongation at break (EB) of tensile samples increased from 5.56 % to 12.2 %, while the tensile strength (TS) decreases from 136.54 % to 68.11 %. Moreover, the contribution of process parameters to the mechanical properties and consistency for UHMWPE tensile samples is 55.97 %–88.37 %, while the contribution of ultrasonic system stability is 11.63 %–44.03 %.

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超声波塑化微注射成型的超高分子量聚乙烯基于新的工艺流程和超声系统结构，以提高力学性能和工艺稳定性

超声塑化微注射成型（UPMIM）技术被认为是超高分子量聚乙烯（UHMWPE）成型的有效手段。但成形过程繁琐，力学性能下降，成型与性能一致性差，严重制约了其进一步应用。本文提出了一种超高分子量聚乙烯微零件的超声成型新方法。首先，利用超声技术，简单、快速地制备了超高分子量聚乙烯超声增塑材料。其次，采用大直径超声电极与塑化腔比的新型UPMIM结构对UHMWPE拉伸样品进行成型；然后，通过灰色关联分析（GRA）得到最佳成型工艺参数。然后，通过贡献分析研究了系统稳定性和工艺参数对力学性能和一致性的影响。最后，与典型的UHMWPE成型方法（压缩成型）和已有的研究成果进行比较，详细分析了该工艺的影响和可行性。结果表明，超声技术可有效制备性能基本不变的超高分子量聚乙烯片（分子量降低0.31%）。超声超声电极与塑化腔直径比较大，可扩大UHMWPE拉伸试样完全填充的工艺窗口，超声系统填充稳定性提高约1.8倍。同时，这种超声体系结构还能抑制UHMWPE的氧化降解，减少分子链断裂。拉伸试样的断裂伸长率（EB）由5.56%提高到12.2%，而拉伸强度（TS）由136.54%降低到68.11%。工艺参数对超高分子量聚乙烯拉伸试样力学性能和一致性的贡献为55.97% ~ 88.37%，超声系统稳定性的贡献为11.63% ~ 44.03%。

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来源期刊

Ultrasonics Sonochemistry 化学-化学综合

CiteScore

15.80

自引率

11.90%

发文量

361

审稿时长

59 days

期刊介绍： Ultrasonics Sonochemistry stands as a premier international journal dedicated to the publication of high-quality research articles primarily focusing on chemical reactions and reactors induced by ultrasonic waves, known as sonochemistry. Beyond chemical reactions, the journal also welcomes contributions related to cavitation-induced events and processing, including sonoluminescence, and the transformation of materials on chemical, physical, and biological levels. Since its inception in 1994, Ultrasonics Sonochemistry has consistently maintained a top ranking in the "Acoustics" category, reflecting its esteemed reputation in the field. The journal publishes exceptional papers covering various areas of ultrasonics and sonochemistry. Its contributions are highly regarded by both academia and industry stakeholders, demonstrating its relevance and impact in advancing research and innovation.