Magneto-rheological model for computational analysis of magnetic micro powder injection molding

• A magneto-rheological model is presented for numerical analysis of magnetic μPIM.
• The present model takes the effects of various processing parameters into account.
• The magneto-rheological behavior is characterized by torque and rotational rheometry.
• The viscosity converges to an upper limit as the magnetic flux density increases.
• The particle size distribution has significant effect on the magneto-rheology.

Magnetic micro powder injection molding is a manufacturing process for mass production of complex shape magnetic micro components. The magnetic performance of the molded part depends on the orientation of magnetic particles. In order to induce specific orientation of anisotropic magnetic particles in the molded product, external magnetic flux is applied to the mold cavity during the filling and cooling stages. In general, rheological behavior of the magnetic feedstock is significantly affected by external magnetic flux, flow shear rate, temperature, powder volume fraction and powder size distribution. For computational analysis of magnetic micro powder injection molding process, one of the most challenging issues has been the magneto-rheological modeling of the feedstock to describe flow and deformation behavior of feedstock under applied external magnetic flux. In this regard, this study introduces recent development of magneto-rheological modeling for magnetic micro powder injection molding.

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