Simulation Study On Shape Control Of Micro-fine Universal Direction Spherical Mechanical Kinematic Pair For In-Mold Micro Assembly Molding

The precision micro manufacturing and precision micro assembly of micro universal spherical mechanical motion pairs are still a technical challenge up to now,the in-mold micro assembly molding process provides an effective means to solve this technical bottleneck problem.However,the coupled impact effect of thermal fluid structure between the secondary molding high temperature melt filling flow and the formed parts may seriously affects the precision and motion performance of the micro assembly interface.Therefore,it is particularly important to innovate and develop highprecision micro assembly forming processes and precise control technologies for thermal fluid solid coupling deformation.In response to the above-mentioned technical difficulties,the self-lubricating liquid film assisted precision in-mold micro assembly molding process and the variable combination forming mold for micro universal spherical mechanical motion pairs have been developed.The molding processing performance and accuracy of the self-lubricating liquid film assisted precision in-mold micro assembly molding process and the variable combination forming mold for micro universal spherical mechanical motion pairs have been simulated and evaluated.The synergistic evolution law of processing accuracy-process conditions-material rheological properties has been clarified.Achieved the following research results:The self-lubricating liquid film assisted precision in-mold micro assembly molding process and the variable combination forming mold for micro universal spherical mechanical motion pairs have been innovatively researched and developed.The simulation evaluation results indicate that the innovatively developed selflubricating liquid film assisted precision in-mold micro assembly molding process and the variable combination forming mold can achieve precision forming and manufacturing of micro universal spherical mechanical motion pairs,can effectively suppress thermal fluid solid coupling deformation,which ensure that the manufacturing dimensional tolerance meets ≤ 30 μm of technical requirements in the industry.The synergistic evolution relationship among machining accuracy,process conditions,material rheological properties was studied by means of system simulation.It was found that the dimensional tolerance of self-lubricating liquid film assisted inmold micro assembly manufacturing of micro universal spherical mechanical motion pairs is positively correlated with the slip coefficient of self-lubricating liquid film,injection temperature,ball coupling depth,reference viscosity,and viscosity ratio,while it is negatively correlated with relaxation time.It can reduce the manufacturing dimensional tolerance of in-mold micro assembly molded micro universal spherical mechanical motion pairs from 211μm to 19μm with a reduction of up to 91% by means of enhancing the slip characteristics of selflubricating function liquid film and reducing the slip coefficient with 1×103,which achieved high-precision in-mold micro assembly molding of micro universal spherical mechanical motion pairs.In order to seek quality through science and ensure success through technology,the comprehensive and refined regulation technologies was constructed for the entire process of the in-micro assembly forming process of micro universal spherical mechanical motion pairs,which provides technical support for industrialized scientific and controllable manufacturing methods...