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Numerical simulation of aluminum alloy 6061 micro-mold fabrication for the production of polymeric microstructures by micro-hot-embossing

Identifieur interne : 000949 ( Main/Exploration ); précédent : 000948; suivant : 000950

Numerical simulation of aluminum alloy 6061 micro-mold fabrication for the production of polymeric microstructures by micro-hot-embossing

Auteurs : N. K. Tran [Singapour] ; Shawn A. Chester [Singapour, États-Unis] ; Y. C. Lam [Singapour] ; L. Anand [Singapour, États-Unis] ; C. Y. Yue [Singapour]

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Abstract

Micro-molds play an important role in the manufacturing process of polymeric micro-devices, e.g. microfluidic devices, as they determine the product quality and the overall production cost. We report here the applicability of a large-deformation, high-temperature, isotropic elastic-viscoplasticity model for the prediction of micron-scale hot-embossing of AA6061. The material parameters in the constitutive model were determined by fitting the stress-strain curves from compression tests at various temperatures and strain rates. The constitutive theory was implemented in a finite element program, and the numerical simulation capability was validated by predicting the response of AA6061 in some representative macro-scale experiments; these experiments had not been used for the determination of the material parameters in the constitutive model. Additional micron-scale hot-embossing experiments on AA6061 were conducted, and by comparing the numerical simulation results to the corresponding physical experiments, we demonstrate that the deformation evolution of AA6061 during micro-hot-embossing is well predicted. The constitutive model and its numerical implementation open the possibility of optimizing the process of making micro-molds for microfluidic devices from AA6061.


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<term>Embossing</term>
<term>Experimental study</term>
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<term>Microfluidics</term>
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<term>Production process</term>
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<term>Thermomechanical properties</term>
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<term>Gaufrage</term>
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<term>Essai compression</term>
<term>Aluminium alliage</term>
<term>Moule</term>
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<term>Miniaturisation</term>
<term>Elastoviscoplasticité</term>
<term>Forme géométrique</term>
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<div type="abstract" xml:lang="en">Micro-molds play an important role in the manufacturing process of polymeric micro-devices, e.g. microfluidic devices, as they determine the product quality and the overall production cost. We report here the applicability of a large-deformation, high-temperature, isotropic elastic-viscoplasticity model for the prediction of micron-scale hot-embossing of AA6061. The material parameters in the constitutive model were determined by fitting the stress-strain curves from compression tests at various temperatures and strain rates. The constitutive theory was implemented in a finite element program, and the numerical simulation capability was validated by predicting the response of AA6061 in some representative macro-scale experiments; these experiments had not been used for the determination of the material parameters in the constitutive model. Additional micron-scale hot-embossing experiments on AA6061 were conducted, and by comparing the numerical simulation results to the corresponding physical experiments, we demonstrate that the deformation evolution of AA6061 during micro-hot-embossing is well predicted. The constitutive model and its numerical implementation open the possibility of optimizing the process of making micro-molds for microfluidic devices from AA6061.</div>
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