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dc.contributor.author
Büttner, Henning
dc.contributor.author
Maradia, Umang
dc.contributor.author
Suarez, Manuel
dc.contributor.author
Stirnimann, Josef
dc.contributor.author
Wegener, Konrad
dc.contributor.editor
Wegener, Konrad
dc.contributor.editor
Wiessner, Moritz
dc.date.accessioned
2022-06-15T11:08:57Z
dc.date.available
2021-01-27T12:15:09Z
dc.date.available
2021-01-27T12:52:26Z
dc.date.available
2021-01-27T14:33:04Z
dc.date.available
2021-01-27T14:40:52Z
dc.date.available
2021-05-28T15:36:09Z
dc.date.available
2022-06-15T11:08:57Z
dc.date.issued
2020
dc.identifier.issn
2212-8271
dc.identifier.other
10.1016/j.procir.2020.03.147
en_US
dc.identifier.uri
http://hdl.handle.net/20.500.11850/465991
dc.identifier.doi
10.3929/ethz-b-000465991
dc.description.abstract
In today’s continuously growing demand for components with increasingly smaller dimensions and features, micro-manufacturing is gaining more significance. For the mass production of plastic components with micro-features, injection molding is particularly suitable and still customary in order to keep target costs. Due to high requirements regarding lifetime and resistance to wear, the molds are made of hardened steel. The shaping of these molds involves electrical discharge machining (EDM). This process allows the generation of micro-structures in micrometer range having small inner radii, high dimensional accuracy and extreme aspect ratio independent of the workpiece hardness. As a work tool for EDM, electrodes made of pure copper (Cu) and tungsten reinforced copper (WCu) are commonly used. The shaping of the electrodes is conducted by micro-milling. For an overall understanding of this process chain, the interaction between micro-milling, micro-EDM, and micro-injection molding must be evaluated. This paper provides knowledge on the limits of each process with regard to burr formation, form accuracy, structure size and aspect ratio. Many factors throughout the process chain affect the size of an attainable micro-feature of a final product. The proper selection of the electrode material is a key factor in the process chain. As the feature size of the electrode defines the dimension of the final product shape, the smallest possible structures have to be found during micro-milling. The dimension of the eroded cavity is defined by the feature size of the electrode in combination with the lateral working gap. Eroded cavities with small inner corner radii and steep flanks can be generated when applying flawless and burr-free electrodes. However, using electrodes in inadequate conditions can lead to worse outcomes. The quality and reliability of the final product are determined to a great extent by the design of the injection molding process. Due to the arising vacuum when evacuating the remaining air in the mold, the inflowing melt is being distributed equally. It must be guaranteed that during injection molding, the mold is thermally-controlled. This prevents premature solidification. Through a combination of these two strategies, a form filling rate in micro-cavities up to 100 % is carried out. By deriving an impeccably adapted process chain, a precise micro-molding can be performed. This leads to the capability of manufacturing bars on a final plastic part with a width and height as low as 55 x 100 µm, and a length of 2 mm.
en_US
dc.format
application/pdf
en_US
dc.language.iso
en
en_US
dc.publisher
Elsevier
en_US
dc.rights.uri
http://creativecommons.org/licenses/by-nc-nd/4.0/
dc.subject
micro-machining
en_US
dc.subject
micro-milling
en_US
dc.subject
micro-die-sinking EDM
en_US
dc.subject
micro-injection molding
en_US
dc.title
Development of Process Chain for Micro-Injection Molding
en_US
dc.type
Conference Paper
dc.rights.license
Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International
dc.date.published
2021-02-02
ethz.book.title
20th CIRP Conference on Electro Physical and Chemical Machining
en_US
ethz.journal.title
Procedia CIRP
ethz.journal.volume
95
en_US
ethz.pages.start
584
en_US
ethz.pages.end
589
en_US
ethz.version.deposit
publishedVersion
en_US
ethz.event
20th CIRP Conference on Electro Physical and Chemical Machining (ISEM 2020) (virtual)
en_US
ethz.event.location
Online
en_US
ethz.event.date
January 19-21, 2021
en_US
ethz.notes
Conference postponed due to Coronavirus (COVID-19). Conference rescheduled from June, 2021 to January, 2022.
en_US
ethz.publication.place
Amsterdam
en_US
ethz.publication.status
published
en_US
ethz.leitzahl
ETH Zürich::00002 - ETH Zürich::00012 - Lehre und Forschung::00007 - Departemente::02130 - Dep. Maschinenbau und Verfahrenstechnik / Dep. of Mechanical and Process Eng.::02623 - Inst. f. Werkzeugmaschinen und Fertigung / Inst. Machine Tools and Manufacturing::03641 - Wegener, Konrad / Wegener, Konrad
en_US
ethz.leitzahl.certified
ETH Zürich::00002 - ETH Zürich::00012 - Lehre und Forschung::00007 - Departemente::02130 - Dep. Maschinenbau und Verfahrenstechnik / Dep. of Mechanical and Process Eng.::02623 - Inst. f. Werkzeugmaschinen und Fertigung / Inst. Machine Tools and Manufacturing::03641 - Wegener, Konrad / Wegener, Konrad
en_US
ethz.date.deposited
2021-01-27T12:15:16Z
ethz.source
FORM
ethz.eth
yes
en_US
ethz.availability
Open access
en_US
ethz.rosetta.installDate
2022-06-15T11:09:08Z
ethz.rosetta.lastUpdated
2022-06-15T11:09:08Z
ethz.rosetta.exportRequired
true
ethz.rosetta.versionExported
true
ethz.COinS
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