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Agency: Cordis | Branch: FP7 | Program: CP | Phase: FoF-ICT-2011.7.1 | Award Amount: 9.30M | Year: 2012

High Pressure Die Casting (HPDC) of light alloys and Plastic Injection Molding (PIM) are two of the most representative large-scale production-line in manufacturing field, which are strategic for the EU-industry largely dominated by SMEs. Due to the high number of process variables involved and to the non-sinchronisation of the process control units, HPDC and PIM are most defect-generating and energy-consumption processes in EU industry. In both, sustainability issue imposes that machines/systems are able to efficiently and ecologically support the production with higher quality, faster delivery times, and shorter times between successive generations of products. The MUSIC is strongly aimed at leading EU-HPDC/PIM factories to cost-based competitive advantage through the necessary transition to a demand-driven industry with lower waste generation, efficiency, robustness and minimum energy consumption. The development and integration of a completely new ICT tool, based on innovative Control and Cognitive system linked to real time monitoring, that allow an active control of quality, avoiding the presence of defects or over-cost by directly acting on the process-machine variables optimization or equipment boundary conditions. The Intelligent Manufacturing approach will work at machine-mold project level to optimise/adapt the production of the specific product and can be extended at factory level to select/plan the appropriated production line. The sensors calibration and quality control of measurements will be the pre-requisite of Intelligent Sensor Network to monitor the real-time production and specific focus will be also devoted to Standardization issues. The challenge of MUSIC is to transform a production-rate-dominated manufacturing field into a quality/efficiency-driven and integration-oriented one to exploit the enormous (and still underestimated) potential of HPDC/PIM through collaborative research and technological development, along the value chain.

Sonne M.R.,Technical University of Denmark | Smistrup K.,APS Technology Inc. | Hannibal M.,Danish Fundamental Metrology | Thorborg J.,Technical University of Denmark | And 3 more authors.
Journal of Materials Processing Technology | Year: 2015

In the presented work, simulations of the deformation process of flexible stamps used for nanoimprint lithography on curved surfaces are presented. The material used for the flexible stamps was polytetrafluoroethylene (PTFE) whose material behavior was found to be viscoelastic-viscoplastic. This behavior was described in a temperature dependent constitutive model consisting of a Zenerbody for the viscoelastic deformation and the Johnson-Cook model for the description of the viscoplastic deformation. The constitutive model was implemented in the general purpose finite element software ABAQUS through a user material subroutine. In order to take the large strains and deformations during the imprinting manufacturing process into account, non-linear geometry was applied in the simulations. The model was first verified through a series of experiments, where nanoimprint lithography on a curved tool insert for injection molding were performed with various process parameters such as temperature, imprinting pressure and flexible stamp thickness. Good agreement between simulations and experimental results was found. The optimum process parameters were then used in the final application, where nanoimprint of a nanostructure giving a color effect was performed numerically and experimentally. Both experiment and simulation showed a mismatch between the defined and measured nanostructures as a result of stretching of the flexible stamp. The model was shown to predict the stretch of the nanostructures with a maximum error of 0.5%, indicating that the model is able to capture the physics of this manufacturing process and can be used to give an insight into the nanoimprinting procedure on curved surfaces. © 2014 Elsevier B.V.

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