Research On The Mechanism Of Polymer Micromachine In-mold Assembly Molding

In-mold assembly molding is an advanced polymer molding technique in which component injection molding process and in-mold assembly process are integrated together and the future important problems of polymer micromachine molding technique will be resolved. Because of the interaction of stresses on the interfaces between adjacent melts and the great influence of the fluid-solid coupling interaction between melt flow and solid microscale component on the polymer micromachine manufacturing accuracy and assembly precision in the molding process, polymer micromachine In-mold assembly molding process has its special transport rule of flow and dynamic characters, which makes its molding mechanism very complicated, and not yet clear, and up to now, the reasearches on related molding theory and molding technique are very rare at home and abroad. Based on the inconsistency between the advance and research shortage of polymer micromachine in-mold assembly technology, the simulation on the polymer micromachine in-mold assembly molding process and the fluid-solid coupling interaction during the molding process was conducted in this paper, and the major achievements are as follows:(1) On the basis of polymer in-mold assembly molding characters and polymer rheological theory, reasonable assumptions were put forward, the fully three-dimensional unsteady pure viscous non-isothermal theoretical model was established to describe the polymer micromachine in-mold assembly molding process and reflect the mechanism of the fluid-solid coupling interactiom. Meanwhile, the corresponding stabled finite element numerical algorithm was established.(2) Based on the finite element numerical simulation technology, the influencing rules of the second stage polymer melt rheological parameters and process parameters on the fluid-solid coupling interaction and fluid-solid coupling deformation of the first stage polymer micro-component were systemcally studied, and the influencing mechanisms were finally disclosured by theoretical analysis.(3) The influencing rules of polymer melt rheological parameters and process parameters on volumetric shrinkage and in-cavity residual stress of polymer in-mold assembly molding micromachine were systemcally studied by finite element numerical simulation, and the influencing mechanisms were finally disclosured by theoretical analysis.(4) Based on the theoretical model and the finite element numerical simulation method for fluid-solid coupling interaction and fluid-solid coupling deformation in this paper, the finite element numerical simulation result of fluid-solid coupling deformation in polymer micromachine in-mold assembly molding process is identical with the Professor Satyandra K Gupta's experimental result. So the theoretical model and the finite element numerical simulation method for fluid-solid coupling interfaction are reliable.