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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

1

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
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Figures

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Deformation of premolded component with flow front progression

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Figure 4

Weld-line location for temporally misaligned gates

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Instantaneous deformation of premolded component during iterative computation

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Forces on premolded component during filling and packing phases

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Figure 7

Premolded component for experiments

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Figure 8

Modular second stage mold design

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Figure 9

Measurement of plastic deformation of premolded component

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Figure 10

Online monitoring system for measuring transverse force on premolded component

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Figure 11

Surrogate strain sensor made of a metallic cantilever beam

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Figure 12

In-mold-assembled mesoscale revolute half joint

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Figure 13

Strain on premolded component as flow front progresses

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Figure 14

Metamodels for individual processes for pin diameter=0.794 mm

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Figure 15

Plastic deformation of mesoscale premolded component relating to the gate misalignment

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Sensitivity of computational model to change in pin diameter

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Figure 17

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

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Figure 18

Modified force model

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Figure 19

Sensitivity of force predictions on prediction of final plastic deformation

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Figure 2

Temporal gate misalignment

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Figure 1

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

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