Towards the analytic characterization of micro and nano surface features using the Biharmonic equation

YesThe prevalence of micromoulded components has steadily increased over recent years. The production of such components is extremely sensitive to a number of variables that may potentially lead to significant changes in the surface geometry, often regarded as a crucial determinant of the product¿s functionality and quality. So far, traditional large-scale quality assessment techniques have been used in micromoulding. However, these techniques are not entirely suitable for small scales . Techniques such as Atomic Force Mi- croscopy (AFM) or White Light Interferometry (WLI) have been used for obtaining full three-dimensional profiles of micromoulded components, pro- ducing large data sets that are very difficult to manage. This work presents a method of characterizing surface features of micro and nano scale based on the use of the Biharmonic equation as means of describing surface profiles whilst guaranteeing tangential (C1) continuity. Thus, the problem of rep- resenting surface features of micromoulded components from massive point clouds is transformed into a boundary-value problem, reducing the amount of data required to describe any given surface feature.The boundary conditions needed for finding a particular solution to the Biharmonic equation are extracted from the data set and the coefficients associated with a suitable analytic solution are used to describe key design parameters or geometric properties of a surface feature. Moreover, the expressions found for describ- ing key design parameters in terms of the analytic solution to the Biharmonic equation may lead to a more suitable quality assessment technique for mi- cromoulding than the criteria currently used. In summary this technique provides a means for compressing point clouds representing surface features whilst providing an analytic description of such features. The work is applicable to many other instances where surface topography is in need of efficient representation

3D simulation of the Hierarchical Multi-Mode Molecular Stress Function constitutive model in an abrupt contraction flow

YesA recent development of the Molecular Stress Function constitutive model, the Hierarchical Multi-Mode Molecular Stress Function (HMMSF) model has been shown to fit a large range of rheometrical data with accuracy, for a large range of polymer melts. We develop a 3D simulation of the HMMSF model and compare it to experimental data for the flow of Lupolen 1840H LDPE through an abrupt 3D contraction flow. We believe this to be the first finite element implementation of the HMMSF model. It is shown that the model gives a striking agreement with experimental vortex opening angles, with very good agreement to full-field birefringence measurements, over a wide range of flow rates. A method to give fully-developed inlet boundary conditions is implemented (in place of using parabolic inlet boundary conditions), which gives a significantly improved match to birefringence measurements in the inlet area, and in low stress areas downstream from the inlet. Alternative constitutive model parameters are assessed following the principle that extensional rheometer data actually provides a ‘lower bound’ for peak extensional viscosity. It is shown that the model robustly maintains an accurate fit to vortex opening angle and full-field birefringence data, provided that both adjustable parameters are kept such that both shear and extensional data are well fitted

An experimental and simulation comparison of a 3-D abrupt contraction flow using the Molecular Stress Function constitutive model

YesThe Molecular Stress Function (MSF) constitutive model with convective constraint release mechanism has been shown to accurately fit a large range of viscometric data, and also shown to give strong vortex growth in flows of LDPE through planar and axisymmetric contractions. This work compares simulation and experimental results for 3-D flows of Lupolen 1840H LDPE through a contraction slit; 3-D effects are introduced by using a slit with a low upstream aspect ratio of 5:3. Comparisons are made with vortex opening angles obtained from streak photography, and also with stress birefringence measurements. The comparisons are made with two versions of the convective constraint release (CCR) mechanism. The simulated vortex angles for one version of the CCR mechanism are found to approach what is seen experimentally. The best-fit value for the stress optical coefficient was found to vary between CCRs and to decrease with flow rate. This is partially explained by different centreline elongational rates with the two CCRs, which in turn is related to different opening angles. A 3-D simulation is compared to the corresponding 2-D simulation. It is shown that both velocity vectors and birefringence show only small changes to around 60% of the distance to the side wall

High speed thermal imaging of complex micromoulding flows

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Surface profiling of micro-scale surface features using Partial Differential Equations

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Micromoulding: extreme process monitoring and in-line product assessment.

NoAdvances in micromoulding technology are now allowing mass production of complex, three-dimensional functional products having sub-milligram masses and carefully tailored surface finishes. In order to create a viable manufacturing process for these components, accurate process monitoring and product evaluation are essential in order to highlight process problems and production of substandard parts. The present study describes work implementing a suite of sensors on a commercial micromoulding machine for detailed process interrogation. Evaluation of demoulded products is performed with a single camera based system combined with custom software to allow for three-dimensional characterisation of products during the process

Characterization of micro-scale surface features using Partial Differential Equations

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Characterization of micro-scale surface features using Partial Differential Equations

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Surface profiling of micro-scale structures using partial differential equation

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