Simulation And Experimental Study Of Extrusion Roller Embossing Process Of Polycarbonate Sheet

Micro-thermal pressuring forming is one of the main methods to achieve the production of polymer sheet tiny structure. However, extrusion roller embossing molding is a new method combining extrusion molding and micro thermoforming, catching more and more attention by continuously producing a large quantities of tiny structures, which is a method of low cost, high efficiency and potential production. The method has a wide prospect in the biological, chemical and other fields. Because of the promotion of ever-increasing market demand and mass production, it is significant to research rheological behavior characteristic of amorphous polymeric materials near the glass transition temperature region and the influence of the extrusion roller embossing process parameter on the rolling print quality.In this paper, firstly, the mechanics state of amorphous polymer with the change of temperature has been analyzed. According to two kinds of deformation behavior of the creep and stress relaxation, polymer viscoelastic model near the glass transition temperature has been established. The Polycarbonate modified generalized Maxwell viscoelastic model parameters with the aid of the stress relaxation experiments using ABAQUS simulation software has been obtained, which provided the theoretical basis for numerical simulation.According to the actual extrusion roller embossing forming process explicit temperature-displacement coupling analysis model has been established in ABAQUS, polymer sheet and the roller die of heat conduction, heat convection of air, and other issues in the roll forming process has been considered. And the influence of the roller embossing process parameters in the roll forming process on the temperature of the polycarbonate sheet and the thermal transfer printing quality has been studied.The tail type extrusion die and roller micro stamping equipment has been designed and manufactured. Combined with single screw extrusion production line, the experiment research of tiny-structure of polycarbonate sheet fabricated by extrusion roller embossing method has been conducted. Besides the experimental results and simulation results has been compared in order to provide the reference for further research to improve the transfer printing plate quality of tiny-structure amorphous polymer sheet manufactured by roller thermal transfer printing technology.