Coupled Simulation Of Injection Molding And Sintering For Shrinkage And Distortion Prediction In Metal Injection Molding

Abstract

Accurate prediction of dimensional shrinkage and distortion is a major challenge in Metal Injection Molding, especially for large and geometrically complex parts. Distortion is influenced by composition-related inhomogeneities and residual stresses inherited from earlier processing steps, as well as by friction, gravity and support conditions during sintering.In this work, injection molding simulations performed with Moldex3D are coupled with sintering simulations using the Simufact Additive Manufacturing module in order to predict shrinkage and distortion along the complete manufacturing chain. Material characterization includes MFI, TGA, DSC, as well as the determination of thermal conductivity and specific heat capacity.Simulation results are validated by geometrical measurements obtained from real injection molding and sintering experiments. The proposed coupled simulation approach enables a more reliable prediction of dimensional changes and supports improved process design and dimensional accuracy in the manufacturing of large MIM components.