Bi-phasic Simulation of Metal Injection Moulding： Constitutive Determinations

IntroductionMetalinjectionmolding (MIM )isexpectedtobeveryefficienttoproducesmalland 3Dcomplicatedpartsinlargeseries .Thistechnologycombinesthewell knownpolymerinjectionmouldingandpowdermetallurgytechnology .AnMIM processincludesfourmainstages[1,2 ] :them…     

A New Explicit Algorithm for Bi-Phasic Mixture Flow in MIM

Metal injection moulding (MIM) is a new technology to manufacture small intricate parts in large quantity. Numerical simulation plays an important role in its development. To predict the specific segregation effect in MIM injection, mixture theory is adopted to model the injection flow by a bi-phasic model. This model conducts to the solution of two-coupled Stokes equations. It is an extremely computational consuming solution in the scope of the traditional algorithms, which induce a serious challenge to cost-effectivity of the MIM simulation. Referred to some methods proposed by Lewis in mono-phasic simulation and the implicit algorithms in MIM simulation, a new explicit algorithm is proposed and realized to perform efficiently this type of bi-phasic flow. Numerically this algorithm is devised to perform the simulation in a fully uncoupled manner except for a global solution of the pressure field in each time step. The physical coupling is taken into account in a sequential pattern by fractional steps. This special algorithm does not need any iteration, so it is straightforward and robust, suitable for MIM simulation and other sorts of simulations for multi-phasic flow.     

微注射成形实验与数值模拟

为研究注射料的流动性和模腔形状的复制能力,加工了含有微流道的模具,在微注射系统上进行了微注射实验.应用基于矢量化显式算法的程序,在不同壁面边界条件下,对微注射实验进行了模拟.结果表明:在注射料温度220 ℃、模具温度40 ℃、注射流量为20 mm3/s、注射时间1 s、保压时间10 s的注射工艺条件下,聚丙烯能较好的复制长5 mm,宽1.5 mm和厚0.8 mm的微流道形状.采用滑移边界条件的微注射模拟结果与实验结果一致,说明微注射中存在边界滑移速度.     

圆柱形模具中金属板条弯曲成形过程模拟

讨论了采用有限变形有限元法所涉及的基本算法，并模拟了圆柱形模具中金属板条弯曲成形过程，模拟结果与试验结果一致并正确地反映了成形过程中出现的现象。     

氧化铝陶瓷粉末固相烧结过程模拟

用膨胀计测量了氧化铝粉末注射成形的烧结过程中试件的单轴收缩率和收缩速率,基于试验数据,设计了相应的参数标定算法,用于确定烧结模型中的单轴粘度和烧结应力,以氧化铝人工髋关节植体为例,将该模型和参数引入到有限元软件Abaqus中实现数值模拟,以预测试件在烧结过程中的收缩和变形,结果表明,用标定的参数的模拟结果与试验结果基本吻合。     

基于全矢量显式算法的双相流填充数值模拟

基于模拟填充过程显式算法,提出用于模拟双相流的全矢量化运算显式算法。在双相流混合理论的基础上,对各类双相流填充及组份分离现象进行模拟。为高效求解耦合的Navier Stokes方程,新算法中的矩阵操作仅在单元一级进行,避免全局求解,使全局操作完全矢量化。新算法的另一显著优势,是采用等阶插值的普通单元,使不可压缩条件通过反馈修正的方法得到满足,通过系统化的光顺处理来避免由于应用等阶插值而导致的自锁。由于全局操作完全矢量化,计算代价与节点的自由度近似成正比,可实现高效的双相流填充及组份分离现象的模拟,满足工业应用中模拟复杂实际问题的需要。     

冲压模拟优化算法与板－模关系处理

本文阐述板件冲压模拟中的算法、模具表达与板－模关系处理问题,采用大变形理论实施有限元过程分析,并给出算例。      

Procast在铸造缩孔预测及其优化中的应用

使用Procast程进行模拟仿真,来预测缩孔、缩松等缺陷,力图对缩孔缺陷的形成机制、特征、影响因素及其解决办法进行讨论。据此采用局部冷却的方式控制铸件凝固顺序,增开溢流槽并且溢流槽保温的有效技术手段转移缺陷的位置,从而保证了铸件内部质量。最后,对比优化工艺后的数值模拟结果,确定了合理的工艺方案,确保铸件浇注成功。     

注射成形填充模拟的修正算法

为提高注射成形过程数值模拟结果的准确性,采用类似迎风法的概念,通过对平流方程作为填充状态控制方程而导致模拟失真原因的分析,提出了相应的数值修正算法.该方法在高效显式数值模拟算法和有限元软件基础上,通过对模型内流体速度场的系统性操作,削弱空气流动速度场对喂料填充的不真实影响,使得填充状态的输送更基于流动前沿面后部的流场作用,并对⊥型和L型模腔进行了数值仿真.结果表明:该方法能有效抑制填充流的失真现象,实现了在流动过程中流向发生大角度变化模腔的正确填充过程.