pps proceeding - Abstract Preview
pps proceeding
Symposium: S03 - Processing Methodologies
Oral Presentation
 
 

Influence of Employing Gas Counter Pressure on Conventional and Metal-Powder Injection Molding

Chen Shia-Chung (1)*, Chang Yung Hsiang (1), Cheng Nien-Tien (2), Chang Jen-An (3), Hsieh Cheng-Chang (2)

(1) R&D Center for Smart Manufacturing, Chung Yuan Christian University, Taiwan. - ChungLi - Taiwan, (2) Dept. of Mechanical Engineering, Chung Yuan Christian University, Taiwan. - ChungLi - Taiwan, (3) National Science and Technology Development Agency, Thailand. - Pathum Thani - Thailand

Injection molding is an effective mass production technology for plastics parts. However, due to the melt flow within a relative thin cavity wall gap, the shear-flow induced molecular and/or fiber orientations result in anisotropic shrinkage and other part properties. In this study, Gas Counter Pressure (GCP) was applied during the injection melt-filling stage via a well-developed gas pressure regulation system. The employment of GCP provides counter force on the melt front leading to the restriction of fountain flow and change the shear flow field. This may reduce the extent of molecular orientation and randomize the fiber orientation. Different levels of counter pressure, molding parameters, percentage of carbon fiber content (15, 30wt%) and gas holding time were conducted in the experiments. The angle distribution of fiber orientation, fiber orientation level within each gapwise layers were measured and analyzed at various part locations gapwisely. It was found that with increased gas counter pressure, fiber becomes more randomly orientated and the anisotropic characteristics of part properties were also reduced. Through-plane conductivity, an index of fiber orientation, improves by 63 %. Metal powder injection molding (MIM) includes several technical steps from the blending of powder and plastics binder, mold design, injection molding, and the post-processing of de-binding, sintering and other secondary operations to final products. Because of the widespread process, MIM often ends with unstable product qualities, such as melt-powder separation, warpage and non-uniform density, etc., leading to low yield rate production. Stainless steel metal powder (316L) with binder of filler wax, active agent stearic acid and polypropylene were used. Employing GCP control to MIM homogenize the perform density and reduce powder-binder separation significantly. The relevant properties in part density, shrinkage, tensile and elongation were improved by 5% to 50% correspondingly.