Research On The Effect Of Polymer Metal Hybrid Technology Process Parameters Adhesive Strength In

PMH technology, which is a newly arisen technology, combines polymer and metal into a system component according some forming principles and suitable process parameters, after the stamping was put into the injection molding as a part insert. The PMH component can provide many satisfied performances such as lower weight, anti-seismic, anticorrosion and so on, and this technology has been more and more widely used in electronic automotive, aerospace and other industrial production.Adhesion strength is the key point in the PMH technology. In this paper, forming process of the mobile shell part, which is made by PMH technology, has been researched. Based on the FEA result, the effect of process parameters on adhesion strength has been analyzed, and finally the process parameter has been optimized.Firstly, based on the principle of the direct adhesion polymer metal hybrid technology, the mobile shell FEA model was set up. A lay of cohesive element, which was characterized by a traction-separation law, has also been built up in each polymer metal interface to simulate the adhesive effect. After the flow analysis and temperature-displacement coupled analysis, the distribution of the residual stress, warping and interface stress has been displayed and analyzed. The resulting enhanced polymer-to-metal adhesion affects the way of injected plastic residual stresses develops while it is cooled from the plastic-melt temperature down to room temperature. Secondly, based on the FEA result, the impacts of different processing parameters, including metal temperature, melt temperature, mold temperature, packing pressure, and packing time, on interface strength has been evaluated using Taguchi method. The S/N ratio analysis result shows that metal temperature have the most significant effect on interface adhesion strength, while mold temperature, packing pressure and packing time have the second strong effect and melt temperature shows least effect.In order to get a deeper research result, the regress model of the relationship between the process parameters and interface stress has been built using regression analysis method, and has been proved to be correct by statistic analysis. Finally, simulated annealing optimization algorithm has been used to get a set of optimized process parameter, for the purpose of lowering the interface stress, enhancing adhesive strength and improving PMH component performance.