Mold filling behaviour of LPIM feedstocks using numerical simulations and real-scale injections

ABSTRACT

This study aims to compare the flow patterns and in-cavity pressures obtained experimentally and numerically for different conditions. Four feedstocks based on 17-4PH stainless steel powder were fully characterised and implemented as material laws in an Autodesk Moldflow package before to obtain numerical simulations that were then validated using real-scale injections. The flow patterns obtained numerically for the different flat bar mold geometries were in good agreement with the experimental flow patterns, showing an almost perfect fit, whereas for the flow patterns of the complex mold geometry, there were some minor discrepancies. The simulated pressure profiles obtained for different mold geometries, feedstock temperatures, mold temperatures and solid loadings were in good agreement with the experimental pressure profiles in terms of trend and pressure values, with maximum relative differences varying from 30 to 64% depending on particular feedstocks and process parameters.

KEYWORDS:

• Low-pressure powder injection molding
• numerical simulation
• metallic powder
• feedstock
• mold filling

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This work was supported by Natural Sciences and Engineering Research Council of Canada: [Grant Number RGPIN-2018-04407].