Giannekas, Nikolaos

Tosello, Guido

Zhang, Yang

Online Research Database In Technology

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Downloaded from orbit.dtu.dk on: Apr 10, 2018A preliminary study on replication and quality correlation of on-part and on-runnerpolymer injection moulded micro featuresGiannekas, Nikolaos; Tosello, Guido; Zhang, YangPublication date:2017Document VersionPublisher's PDF, also known as Version of recordLink back to DTU OrbitCitation (APA):Giannekas, N., Tosello, G., & Zhang, Y. (2017). A preliminary study on replication and quality correlation of on-part and on-runner polymer injection moulded micro features. Poster session presented at Polymer Replicationon Nanoscale 2017, Aachen, Germany.N. Giannekas, G. Tosello, Y. Zhang A preliminary study on replication and quality correlation of on-part and on-runner polymer injection moulded micro featuresDepartment of Mechanical Engineering, Technical University of Denmark (DTU), Produktionstorvet, Building 427A, Kgs. Lyngby, DK-2800, DenmarkAbstractInjection molding is increasingly gaining place in manufacturing of polymercomponents as is can ensure a cost efficient production with short cycletimes. To ensure the quality of the produced parts and the stability of theprocess it is essential to perform frequent metrological inspections. Incontrast to injection moulding’s short cycle time, a metrological qualitycontrol can require a significant amount of time. The late detection of theproblem can result to high losses and scrap rate. This work presents analternative approach to process monitoring and part quality control withfast off/in-line metrology of physical part quality indicators (“ProductFingerprint”).The proposed approach is based on the concept of metrology applied todedicated micro pillar features, positioned on the runners, similar or equalto those in the part in order to access the quality of the produced plasticparts. A designed experiment was employed to map the experimentalspace and quantify the pillars replication depending on position andprocessing parameter combinations. The pillars were assessed and themain effects of the processing parameters, were calculated to reveal thatthe effects of process parameter changes were similar in all measurementpositions.References[1]M. Calaon, “Process chain validation in micro and nano replication,” PhD Thesis, Technical University of Denmark. Department of Mechanical Engineering, 2014.[2]R. X. Gao, X. Tang, G. Gordon, and D. O. Kazmer, “Online product quality monitoring through in-process measurement,” CIRP Ann. - Manuf. Technol., vol. 63, pp. 493–496, 2014.[3]D. Kusić, T. Kek, J. M. Slabe, R. Svečko, and J. Grum, “The impact of process parameters on test specimen deviations and their correlation with AE signals captured during the injection moulding cycle,” Polym. Test., vol. 32, no. 3, pp. 583–593, 2013.Fig. 1: Pillar micro features shape and dimensionEffects of process conditions and position on pillar height replication Fig. 3: Influence of injection speed, packing pressure, melt (Tmelt) and mould (Tmould) temperature on pillar heightsdepending on measurement positions. High melt temperature results to better pillar replication, beside position RP2(runner) were the parameter causes opposite effects, though in smaller magnitude. Injection speed has the next biggesteffect with the same effect behaviour to be present in all positions, producing better replicated features.Experimental Run No#Run 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Tmelt [°C] 220 260 220 260 220 260 220 260 220 260 220 260 220 260 220 260Tmould [°C] 40 40 60 60 40 40 60 60 40 40 60 60 40 40 60 60Inj.Speed [mm/s] 100 100 100 100 140 140 140 140 100 100 100 100 140 140 140 140Pack.Pressure [bar] 440 440 440 440 440 440 440 440 540 540 540 540 540 540 540 540Table 1: 24 full factorial design Experimental set-up• Design of Experiments (DOE) technique was employed• 24 full factorial design (Table 1 ) in ABS material• Melt temperature ⇒ 220˚C, 260 ˚C• Mould temperature ⇒ 40˚C, 60 ˚C• Injection speed ⇒ 100 mm/s, 140 mm/s• Packing pressure ⇒ 440 bar, 540 bar•4 measurement positions for each part• 3 pillars per position- 4 profiles per pillar•Alicona (infinite focus): focus variation microscope⇔• Constant scanning settings:• Objective x20• Scanning area of 714×542 µm2• Centered on pillar center• Vertical resolution of 299 nm• Lateral resolution of 2,93 µmAcknowledgementsThis paper reports work undertaken within theframework of the project MADE (ManufacturingAcademy of Denmark). MADE is a collaborativeresearch project supported both by the industrialpartners and by the Innovation Fund.ConclusionsA designed experiment was employed to map theprocess window and quantify the pillars replicationdepending on position and process conditions ineach run. The replication of the pillars was evaluatedand the effects of the processing parameters werecalculated to reveal that the effects of processparameter changes were similar in all measurementpositions; It is indicated that the proposed approachcan be used to assess part quality based on off-part/on-runner micro features.Fig. 2: Pillar height assessment with SPIP: Averaging of the maximum values from 4 profiles Objectives and geometry• Objective ⇒ To study the replication and qualitycorrelation of on-part and on-runner polymer injectionmoulded micro pillar features• Increase quality of pillars ⇔ better products andprocess stability• Correlate quality on part and runner ⇔ Fast QA ,reduction of metrological effort•Tablet biochip 20×20×2mm3 geometry• Key injection molding parameters• ⇒Melt temperature• ⇒Mould temperature•Key geometry parameters• ⇒ Pillar position• ⇒ Injection speed• ⇒ Packing Pressure

A preliminary study on replication and quality correlation of on-part and on-runner polymer injection moulded micro features

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A preliminary study on replication and quality correlation of on-part and on-runner polymer injection moulded micro features

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