The finite element analysis of melt flow behaviour in micro-injection moulding

Micro-injection moulding as a replication method is one of the key technologies for micromanufacture. The understanding of process constraints for a selected production route is essential both at the design stage and during mass production. In this research, an existing finite element analysis system is used to verify the effects of four process parameters: the melt and mould temperatures, injection speed, and part thickness. Special attention is paid to the melt flow sensitivity when filling microchannels, particularly the factors affecting the shear rate, pressure, and temperature. In particular, the simulation model was used to investigate the flow behaviour of two polymer materials, polypropylene and acrylonitrile butadiene styrene, by varying the process parameters. Then, the results of this investigation were compared with those reported in an experimental study. Conclusions are made about the accuracy and sensitivity of the proposed simulation model. © IMechE 2008.