Simulation of powder injection moulding conditions using cadmould program

Purpose: Development of a new generation tool materials on the basis of high speed-steel manufactured by Powder Injection Moulding. To investigate formability of the polymer-powder slurry in which the HS12-1-5-5 (T15) high-speed steel powder was used, as well as the HD-PE polyethylene and paraffin, the „Cadmould” commercial software was employed, developed mostly for simulation of the powder injection moulding of the thermoplastic and composites. Design/methodology/approach: Powder metallurgy, powder injection moulding, sintering, microstructure examination, symulation of injection moulding. Findings: Simulation of powder injection moulding was preceded by the rheological tests, which made obtaining possible of the data indispensable for modelling, pertaining to the polymer-powder slurry viscosity. The portion of particles reinforcing the composite is usually lower than powder portion in mixtures used for forming and next binding agent degradation and sintering. The big powder portion is often the reason for the high viscosity of the mixture and problems with its forming. However, simulation results revealed that the fabricated polymer-powder mixture may be injected, which was confirmed by carrying out powder injection moulding on a typical Arburg injection moulding machine using in the industry. Practical implications: Application of powder injection moulding to manufacturing of high speed steel matrix composites gives the possibility to obtain tool materials with the relative high ductility characteristic of steel and high hardness and wear resistance typical for cemented carbides. Originality/value: Application of symulation of powder injection moulding conditions using cadmould program gives the possibility to reduce cost of expensive injection mould and control the injection conditions.