SiMiFo: Practical and simulative analysis of micro-moulded in-mould assembly plastic/metal composites

Fundamental Investigation and Simulation of Microstructure Filling and Material Properties for Optimised Joining Connections

Plastic/metal hybrid components can achieve weight-reduced and cost-efficient products with high functional integration by combining the specific material advantages. The production of the material composite poses a challenge. The innovative joining approach of micro-form-fit bonding, i.e. the back-injection of large-area microstructures, allows the advantages of form-fit bonding to be combined with the advantages of material bonding.

To date, there are no design guidelines available for this joining approach that reflect the dependency on the structural geometry, arrangement and the moulding compound used. This is mainly due to the fact that the microstructure geometry is not fully defined by the laser process and the challenges involved in calculating and simulating the filling of microstructures. However, the filling of the microstructures has a significant influence on the bond strength, which is why this is to be investigated fundamentally and comprehensively as part of the research project.

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In addition to the filling of the microstructures in the injection moulding process, the resulting material properties such as the crystallisation of the plastic moulding compound in the area of the microstructures are also considered. The aim is to predict the structural filling and the material properties depending on the structural geometry, the moulding compound used, the sheet material used, the process parameters and the geometry of the moulded part. To this end, comprehensive practical analyses are carried out and various simulative approaches are considered.

Project data, funding and thanks

We would like to thank the DFG for funding the project (funding reference HO 4776/92-1) and the project partners for their cooperation

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