Numerical analysis of filling stage during powder injection moulding: effects of feedstock rheology and mixing conditions

Numerical modelling of powder injection moulding (PIM) is a powerful tool to optimise mould design based on the rheology of the feedstock. In the present study, a finite element based simulation is utilised in evaluating the effect of feedstock rheology and confirming the effect of mixing on the mould filling phase of the PIM process. The numerical simulation, considering the slip layer model for non-isothermal flow analysis, confirms the experimental results that a feedstock with lower viscosity and higher homogeneity requires lower injection pressures and clamping forces during the mould filling stage. Results amply illustrate the effect of mixing conditions on moulding pressure and temperature related process parameters and flow stability during mould filling stage.