Research Papers

Modeling and Characterization to Minimize Effects of Melt Flow Fronts on Premolded Component Deformation During In-Mold Assembly of Mesoscale Revolute Joints

[+] Author and Article Information
A. Ananthanarayanan

Department of Mechanical Engineering, University of Maryland, College Park, MD 20742arvinda@umd.edu

S. K. Gupta1

Department of Mechanical Engineering and Institute of Systems Research, University of Maryland, College Park MD 20742skgupta@eng.umd.edu

H. A. Bruck

Department of Mechanical Engineering, University of Maryland, College Park, MD 20742bruck@eng.umd.edu


Corresponding author.

J. Manuf. Sci. Eng 132(4), 041006 (Jul 22, 2010) (9 pages) doi:10.1115/1.4001549 History: Received March 27, 2009; Revised February 15, 2010; Published July 22, 2010; Online July 22, 2010

In-mold assembly can be used to create mesoscale articulating polymeric joints that enable the miniaturization of devices, reduction in production costs, and increase in throughput. One of the major challenges in miniaturizing devices using the in-mold assembly is to develop appropriate characterization techniques and modeling approaches for the interaction between polymer melt flow fronts and premolded components. When a high speed, high temperature second stage melt comes in contact with a premolded mesoscale component that has similar melting temperatures, the premolded component can experience a significant plastic deformation due to the thermal softening and the force associated with impingement of the melt flow front. In our previous work, we developed methods to inhibit the plastic deformation by supporting the ends of the mesoscale premolded components. In this paper, we present an alternative strategy for controlling premolded component deformations. This involves a mesoscale in-mold assembly strategy that has a multigate mold design for bidirectional filling. This strategy permits in-mold assembly using polymers with comparable melting points. This paper demonstrates the technical feasibility of manufacturing in-mold-assembled mesoscale revolute joints using this bidirectional filling strategy. An experimental technique was developed for characterizing the transient impact force of the melt flow front on premolded components inside of a mold. The experimental data were used to validate a new computational model for predicting the effects of the melt flow front position in order to minimize the plastic deformation of premolded component using the bidirectional filling strategy. This paper also investigates the effects of the flow front position on the force applied on the premolded component and its corresponding plastic deformation.

Copyright © 2010 by American Society of Mechanical Engineers
Your Session has timed out. Please sign back in to continue.



Grahic Jump Location
Figure 3

Deformation of premolded component with flow front progression

Grahic Jump Location
Figure 4

Weld-line location for temporally misaligned gates

Grahic Jump Location
Figure 5

Instantaneous deformation of premolded component during iterative computation

Grahic Jump Location
Figure 6

Forces on premolded component during filling and packing phases

Grahic Jump Location
Figure 7

Premolded component for experiments

Grahic Jump Location
Figure 8

Modular second stage mold design

Grahic Jump Location
Figure 9

Measurement of plastic deformation of premolded component

Grahic Jump Location
Figure 10

Online monitoring system for measuring transverse force on premolded component

Grahic Jump Location
Figure 11

Surrogate strain sensor made of a metallic cantilever beam

Grahic Jump Location
Figure 12

In-mold-assembled mesoscale revolute half joint

Grahic Jump Location
Figure 13

Strain on premolded component as flow front progresses

Grahic Jump Location
Figure 14

Metamodels for individual processes for pin diameter=0.794 mm

Grahic Jump Location
Figure 15

Plastic deformation of mesoscale premolded component relating to the gate misalignment

Grahic Jump Location
Figure 16

Sensitivity of computational model to change in pin diameter

Grahic Jump Location
Figure 17

Elastic deformation of in-mold-assembled revolute joint during actuation

Grahic Jump Location
Figure 18

Modified force model

Grahic Jump Location
Figure 19

Sensitivity of force predictions on prediction of final plastic deformation

Grahic Jump Location
Figure 2

Temporal gate misalignment

Grahic Jump Location
Figure 1

Schematic of the two-stage mold design using multigate bidirectional filling strategy




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In