Abstract
In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM) process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE) simulation. PE (high density polyethylene (HDPE) and low density polyethylene (LDPE)) and polypropylene (PP) resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made.
Highlights
Structural products operating under a high pressure and load environment have been developed using metal
There are several important blanking tools and bending dies meant for manufacturing metal plates and internal structure parts
In order to check the feasibility of the sacrificed part in the metal injection molding process, the pre-injection molding was implemented with the transparent polymer resin employing sacrificed polymer parts as inserts
Summary
Structural products operating under a high pressure and load environment have been developed using metal. The honeycomb structure is a well-known and useful structure able to endure severe compression load conditions [1]. These types of plates were used for insulating panels, pressure vessel chassis and floor panel etc. When a structural plate with a honeycomb shape is made with metal, there are several necessary parts, such as the upper plate, lower plate and inner parts. There are secondary processes, such as welding, joining (e.g., bolting, riveting, etc.) and bonding methods, to accomplish a honeycomb structure. These schemes, which need other facilities, may be time-consuming and expensive.
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
