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Temperature effects on DLC coated micro moulds

C.A. Griffiths, A. Rees, R.M. Kerton, O.V. Fonseca, Andrew Rees, Rhian Kerton, Christian Griffiths

Surface and Coatings Technology, Volume: 307, Pages: 28 - 37

Swansea University Authors: Andrew Rees, Rhian Kerton, Christian Griffiths

DOI (Published version): 10.1016/j.surfcoat.2016.08.034

Abstract

Microinjection moulding is a key enabling technology for replicating miniaturized components and parts with functional features at the micrometer and even sub-micrometer length scale. The micro moulding tools used in the process chain are critical for delivering high quality parts for the duration o...

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Published in: Surface and Coatings Technology
Published: 2016
URI: https://cronfa.swan.ac.uk/Record/cronfa29594
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spelling 2016-10-03T16:57:38.5799387 v2 29594 2016-08-17 Temperature effects on DLC coated micro moulds e43e88c74976e714e1d669a898f8470d Andrew Rees Andrew Rees true false 1467a7b9d7e8493f15a1dc3a80332729 Rhian Kerton Rhian Kerton true false 84c202c256a2950fbc52314df6ec4914 Christian Griffiths Christian Griffiths true false 2016-08-17 MECH Microinjection moulding is a key enabling technology for replicating miniaturized components and parts with functional features at the micrometer and even sub-micrometer length scale. The micro moulding tools used in the process chain are critical for delivering high quality parts for the duration of the product life cycle, and recently tool coatings such as Diamond-like carbon (DLC) have been used to extend their use and enhance the performance. The micro injection moulding process has high injection speeds with cyclic heat transfer characteristics, and little is understood on how the localised heat transfer at the surface will influence the DLC surface coating delamination and cracking. In this research a microinjection moulding process using three different polymers, Polypropylene (PP), Acrylonitrile butadiene styrene (ABS) and Polyether ether ketone (PEEK) is studied. Finite element analysis (FEA) simulation is utilised to identify the process temperature factors that lead to tool thermal expansion and dimensional changes that directly impact the life cycle of the coating. The theoretical and FEA results show that the mould material and the two coatings experience a significantly different thermal expansion from each other. It has also been shown that at the micro scale heat loss at the tool surface is dominant, and the variation in heat has a significant influence on the different thermal expansion rates. In particular the DLC coated micro rib features are particularly susceptible to high variations in heat transfer. The research identifies areas of the tool surface that experience sudden heat variation across the part surface, and concludes that through process optimisation it is possible to reduce the potential for DLC coating delamination and cracking during service. Journal Article Surface and Coatings Technology 307 28 37 15 12 2016 2016-12-15 10.1016/j.surfcoat.2016.08.034 COLLEGE NANME Mechanical Engineering COLLEGE CODE MECH Swansea University 2016-10-03T16:57:38.5799387 2016-08-17T13:33:22.0174171 Faculty of Science and Engineering School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering C.A. Griffiths 1 A. Rees 2 R.M. Kerton 3 O.V. Fonseca 4 Andrew Rees 5 Rhian Kerton 6 Christian Griffiths 7 0029594-817201613740PM.pdf griffiths2016.pdf 2016-08-17T13:37:40.5300000 Output 924966 application/pdf Accepted Manuscript true 2017-08-16T00:00:00.0000000 true
title Temperature effects on DLC coated micro moulds
spellingShingle Temperature effects on DLC coated micro moulds
Andrew Rees
Rhian Kerton
Christian Griffiths
title_short Temperature effects on DLC coated micro moulds
title_full Temperature effects on DLC coated micro moulds
title_fullStr Temperature effects on DLC coated micro moulds
title_full_unstemmed Temperature effects on DLC coated micro moulds
title_sort Temperature effects on DLC coated micro moulds
author_id_str_mv e43e88c74976e714e1d669a898f8470d
1467a7b9d7e8493f15a1dc3a80332729
84c202c256a2950fbc52314df6ec4914
author_id_fullname_str_mv e43e88c74976e714e1d669a898f8470d_***_Andrew Rees
1467a7b9d7e8493f15a1dc3a80332729_***_Rhian Kerton
84c202c256a2950fbc52314df6ec4914_***_Christian Griffiths
author Andrew Rees
Rhian Kerton
Christian Griffiths
author2 C.A. Griffiths
A. Rees
R.M. Kerton
O.V. Fonseca
Andrew Rees
Rhian Kerton
Christian Griffiths
format Journal article
container_title Surface and Coatings Technology
container_volume 307
container_start_page 28
publishDate 2016
institution Swansea University
doi_str_mv 10.1016/j.surfcoat.2016.08.034
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering
document_store_str 1
active_str 0
description Microinjection moulding is a key enabling technology for replicating miniaturized components and parts with functional features at the micrometer and even sub-micrometer length scale. The micro moulding tools used in the process chain are critical for delivering high quality parts for the duration of the product life cycle, and recently tool coatings such as Diamond-like carbon (DLC) have been used to extend their use and enhance the performance. The micro injection moulding process has high injection speeds with cyclic heat transfer characteristics, and little is understood on how the localised heat transfer at the surface will influence the DLC surface coating delamination and cracking. In this research a microinjection moulding process using three different polymers, Polypropylene (PP), Acrylonitrile butadiene styrene (ABS) and Polyether ether ketone (PEEK) is studied. Finite element analysis (FEA) simulation is utilised to identify the process temperature factors that lead to tool thermal expansion and dimensional changes that directly impact the life cycle of the coating. The theoretical and FEA results show that the mould material and the two coatings experience a significantly different thermal expansion from each other. It has also been shown that at the micro scale heat loss at the tool surface is dominant, and the variation in heat has a significant influence on the different thermal expansion rates. In particular the DLC coated micro rib features are particularly susceptible to high variations in heat transfer. The research identifies areas of the tool surface that experience sudden heat variation across the part surface, and concludes that through process optimisation it is possible to reduce the potential for DLC coating delamination and cracking during service.
published_date 2016-12-15T03:36:00Z
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