Constitutive model and numerical simulation for injection molding of MgTiO₃ ceramic parts

Abstract

In order to predict the powder flow law of the injection molding process of MgTiO₃ ceramic parts with complex structures, a constitutive model and numerical simulation method for MgTiO₃ ceramic injection molding were established based on the Hunt method. The material parameters of MgTiO₃ such as elastic modulus, Poisson ratio, glass transition temperature, thermal conductivity and specific heat capacity were measured. Based on the fitting curve and the material parameters measured, the cross-WLF viscosity model and P-V-T model required for MgTiO₃ ceramic injection molding were optimized. Furthermore, the influence of process parameters on mold filling flow and distribution of parts defects was researched. It was found that the gate position, injection speed and melt temperature have greater influence on mold filling flow and the packing process has an obvious effect on parts’ defects. On this basis, the MgTiO₃ ceramic parts injection molding experiment verification was carried out. By comparing the experimental results with the simulated results, it is found that the deformation error is within 1.5% and the density error is within 1%. Therefore, this research provided theoretical guidance for the engineering application of MgTiO₃ ceramic parts fabricated by injection molding.

Keywords

MgTiO₃ / ceramic injection molding / constitutive model / process parameters

References

[1] GongWPhase stability and anti-reduction sintering of magnesium metatitanate microwave dielectric ceramics [D], 2018, Wuhan, Huazhong University of Science and Technology(in Chinese)

[2] ZhouG, FengL-b, ZhouZ-y, XiaoH, LiX-hui. Ceramic powder injection molding technology and research progress [J]. Materials Research and Application, 2018, 12(2): 75-81(in Chinese)

[3] KiharaJ. Powder-binder flow simulation in injection moulding [J]. Antioxidants & Redox Signaling, 2000, 2(4): 739-752

[4] TsengW J, ChiangD. Influence of molding variables on defect formation and mechanical strength of injection-molded ceramics [J]. Journal of Materials Processing Technology, 1998, 84(1–3): 229-235

[5] ToselloG, MarhöferD M, IslamA, MüllerT, PlewaK, PiotterV. Comprehensive characterization and material modeling for ceramic injection molding simulation performance validations [J]. The International Journal of Advanced Manufacturing Technology, 2019, 102: 225-240

[6] YAN Zhi-yun, YAN You-lan. Powder injection molding simulation analysis of ceramic screw [J]. Plastics Manufacture, 2010(4): 89–92. (in Chinese)

[7] KiharaS, GoudaT, MatsunagaK, FunatsuK. Numerical simulation of three-dimensional viscoelastic flow within dies [J]. Polymer Engineering and Science, 1999, 39(1): 152-163

[8] HuntK N, EvansJ R G, WoodthorpeJ. Computer modelling of the origin of defects in ceramic injection moulding [J]. Journal of Materials Science, 1991, 26(19): 5229-5238

[9] HuntK N, EvansJ R G, WoodthorpeJ. Computer modelling of the origin of defects in ceramic injection moulding [J]. Journal of Materials Science, 1991, 26(19): 5229-5238

[10] HuntK N, EvansJ, WoodthorpeJ. Computer modelling of the origin of defects in ceramic injection moulding-Part I Measurement of thermal properties [J]. Journal of Materials Science, 1991, 26(2): 285-291

[11] KwonT H, ParkJ B. Finite element analysis modeling of powder injection molding filling process including yield stress and slip phenomena [J]. Polymer Engineering & Science, 1995, 35(9): 741-753

[12] HwangC J, KwonT H. A full 3D finite element analysis of the powder injection molding filling process including slip phenomena [J]. Polymer Engineering & Science, 2010, 42(1): 33-50

[13] HuP-cheng. Ceramic injection molding technology and research progress [J]. China Ceramic Industry, 2018, 25(5): 14-18(in Chinese)

[14] AttiaU M, AlcockJ R. Fabrication of ceramic micro-scale hollow components by micro-powder injection moulding [J]. Journal of the European Ceramic Society, 2010, 30(6): 1199-1204

[15] RuhA, HanemannT, HeldeleR, PiotterV, Ritzhaupt-KleisslH J, HausseltJ, HanemannT, HeldeleR, HausseltJ. Development of two-component micropowder injection molding (2C MicroPIM): Characteristics of applicable materials [J]. International Journal of Applied Ceramic Technology, 2011, 8(1): 194-202

[16] GermanR M, HensK H. Identification of the effects of key powder characteristics on powder injection moulding [J]. Metal Powder Report, 1992, 47(10): 55

[17] DengL-j, QiaoL, ZhengJ-w, YingY, YuJ, LiW-c, CheS-l, CaiW. Injection molding, debinding and sintering of ZrO₂ ceramic modified by silane couping agent [J]. Journal of the European Ceramic Society, 2019, 4041566-1573

[18] EnríquezE, BergesC, FuertesV, GallegoA, NaranjoJ A, HerranzG, FernándezJ F. Ceramic injection Moulding of engineered glass-ceramics: Boosting the rare-earth free photoluminescence [J]. Ceramics International, 2020, 46(7): 9334-9341

[19] EscobarC F, DosS L A. New eco-friendly binder based on natural rubber for ceramic injection molding process [J]. Journal of the European Ceramic Society, 2015, 35(13): 3567-3575

[20] LenzJ, EnnetiR K, OnbattuvelliV, KateK, MartinR, AtreS. Powder injection molding of ceramic engine components for transportation [J]. JOM, 2012, 64(3): 388-392

[21] HnatkovaE, HausnerovaB, FilipP. Evaluation of powder loading and flow properties of Al₂O₃ ceramic injection molding injection materials treated with stearic acid [J]. Ceramics International, 2019, 45(16): 20084-20090

[22] XiaoJ, ZengX-y, LiM, DongP, WuH, XuM-l, LinY, LiuJ, XieY-min. Effect of pre-calcined ceramic powders at different temperatures on Ni-YSZ anode-supported SOFC cell/stack by low pressure injection molding [J]. Ceramics International, 2019, 45(16): 20066-20072