Numerical simulation of powder injection moulding filling process for intricate parts

A numerical simulation of the powder injection moulding filling process of the 57 vol.% YG8 feedstock was performed using the finite element analysis software ANSYS, for the no slip boundary condition employed at the wall. The flow process of the feedstock around obstacles was estimated; the transient distributions of temperature, velocity, pressure, viscosity and their development in the moulded part were simulated. The results of the simulation showed that the transient temperature in certain areas becomes higher than the initial temperature of the feedstock and the distribution of viscosity at the end of the filling stage is very complicated. The simulation results show that the powder binder separation or the density gradients in the component may occur during the injection moulding process. The defects such as weld lines, voids, sink marks and the possible defect sites were analysed. The simulation results are validated with real production and experimental research data.