Abstract
The surface finish of an injection mould influences the quality of the moulded polymer optic parts. In order to improve and control the surface finish of the mould it is important to be able to predict the material removal during the polishing process of this mould. The aim of this work is to predict the material removal during the polishing process, comparing the results obtained from polishing attempts on steel samples and the results obtained from a simulation model. A simulation model is developed with the abrasive wear Holm-Archard equation in ANSYS. This simulation model will help to eliminate the iterative trial and error polishing, therefore facilitating the steel mould production.
Highlights
Plastic injection moulding is a manufacturing process, where melted plastic is injected into a mould and parts can be produced
To reduce the costs of the polishing process on moulds production, robot polishing is starting to be more used as it brings more stability and reproduction to the moulds (Speich, Börret, Harrison, & DeSilva, 2013)
Wear FEM simulation model In order to simulate the material removal conducted during the polishing attempts on steel samples, a two part simulation model was constructed
Summary
Plastic injection moulding is a manufacturing process, where melted plastic is injected into a mould and parts can be produced. This polishing process could improve the surface roughness to 3 nm and the shape deviation to approximately 4 μm. The right illustration the measurement of another steel sample, where a linear tool path was used and a shape deviation of 8.3 μm was achieved This being said, it is nowadays possible to obtain a much better geometrical form, even before the polishing process, by using an HSC machine, which makes this research even more interesting. The objective of this work is to predict the material removal during robot polishing on steel samples For this reason a simulation model was developed using the Finite Element Method software ANSYS. In the developed simulation model, the Holm-Archard equation is implemented, simulating the same mechanism as in the polishing attempts
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