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Micromachines 2018, 9(2), 58; https://doi.org/10.3390/mi9020058

Effect of Process Parameters on Flow Length and Flash Formation in Injection Moulding of High Aspect Ratio Polymeric Micro Features

1
Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, DTU Building 427A, DK-2800 Kongens Lyngby, Denmark
2
Faculty of Engineering, Production Engineering and Mechanical Design Department, Mansoura University, Elgomhouria St., Mansoura City 35516, Egypt
*
Author to whom correspondence should be addressed.
Received: 14 December 2017 / Revised: 26 January 2018 / Accepted: 29 January 2018 / Published: 31 January 2018
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Abstract

This paper reports an investigation of the effects of process parameters on the quality characteristics of polymeric parts produced by micro injection moulding (μIM) with two different materials. Four injection moulding process parameters (injection velocity, holding pressure, melt temperature and mould temperature) were investigated using Polypropylene (PP) and Acrylonitrile Butadiene Styrene (ABS). Three key characteristics of the mouldings were evaluated with respect to process settings and the material employed: part mass, flow length and flash formation. The experimentation employs a test part with four micro fingers with different aspect ratios (from 21 up to 150) and was carried out according to the Design of Experiments (DOE) statistical technique. The results show that holding pressure and injection velocity are the most influential parameters on part mass with a direct effect for both materials. Both parameters have a similar effect on flow length for both PP and ABS at all aspect ratios and have higher effects as the feature thickness decreased below 300 μm. The study shows that for the investigated materials the injection speed and packing pressure were the most influential parameters for increasing the amount of flash formation, with relative effects consistent for both materials. Higher melt and mould temperatures settings were less influential parameters for increasing the flash amount when moulding with both materials. Of the two investigated materials, PP was the one exhibiting more flash formation as compared with ABS, when corresponding injection moulding parameters settings for both materials were considered. View Full-Text
Keywords: micro injection moulding; design of experiments; part mass; flow length; flash formation micro injection moulding; design of experiments; part mass; flow length; flash formation
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Eladl, A.; Mostafa, R.; Islam, A.; Loaldi, D.; Soltan, H.; Hansen, H.N.; Tosello, G. Effect of Process Parameters on Flow Length and Flash Formation in Injection Moulding of High Aspect Ratio Polymeric Micro Features. Micromachines 2018, 9, 58.

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