Modeling and simulation of metal injection molding (MIM)

Abstract

Powder injection molding (PIM) is a means of mass-producing various metal or ceramic three-dimensional components in large production quantities at low costs. Computer simulations used for plastic injection molding and powder metallurgy have been applied to PIM, but the high solid content in the powder-binder feedstock makes for differences in density, conductivity, shear rate sensitivity, and other factors. Thus, simulations for the PIM process build on the success demonstrated in plastics and powder metallurgy, but rely on modifications to properly handle mixing, molding, debinding, and sintering. In this chapter, the basic models and numerical simulations are introduced in sequence to treat mixing, molding, debinding, and sintering to make predictions relevant to defect-free, high-quality production. The simulations are applied to optimization for a few applications. © 2019 Elsevier Ltd.