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Incorporating Manufacturing Process Simulations to Enhance Performance Predictions of Injection Moulded Metamaterials

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Abstract

Purpose

Locally resonant metamaterials are engineered structures, typically comprising a host structure with resonant structures added or included on a sub wavelength scale. Their interaction leads to stopbands, which are frequency ranges in which no free wave propagation is allowed, enabling strong vibration reduction. At present, metamaterials are mostly realized in an ad hoc manner, as mostly academic demonstrators are considered and the currently used manufacturing approaches are not yet suited for mass production. Moreover, manufacturing induced changes in metamaterial geometry and material properties are hard to account for in the early design process, which can result in off-design metamaterial performance. In this work, injection moulding is proposed as a mass-manufacturing method for resonators, and dedicated injection moulding process simulations are incorporated in the metamaterial performance predictions to account for the influence of manufacturing induced changes.

Methods

The benefits of incorporating manufacturing simulations in metamaterial performance predictions are investigated for three injection moulded resonator types. Three dedicated mould inserts were manufactured, each possessing a resonator product cavity, and several sets of resonators are produced in two different materials. The masses and main dimensions of the produced resonators are measured, and their eigenfrequencies are determined using laser vibrometry. To predict the as-produced resonator shape and density distribution, injection moulding simulations are performed using the commercial software Moldex3D 2022. The resulting model meshes are next translated to structural dynamic finite element models to determine the eigenfrequencies and stopbands.

Results and Conclusion

Incorporating injection moulding simulations in structural dynamic modelling clearly improves the eigenfrequency predictions of the manufactured resonators as well as the metamaterial stopband predictions.

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Data availability

The datasets generated during and/or analysed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The research of K. Steijvers (fellowship no. 1S63423N) and L. Van Belle (fellowship no. 1271621N) is funded by a grant from the Research Foundation – Flanders (FWO). The Research Foundation Flanders (FWO) and São Paulo Research Foundation-Brazil (FAPESP) are gratefully acknowledged for their support through the bilateral research cooperation project (FWO no. G0F9922N, FAPESP no. 21/05510-3). Internal Funds KU Leuven are gratefully acknowledged for their support. This research was also partially supported by Flanders Make, the strategic research centre for the manufacturing industry. VLAIO (Flanders Innovation & Entrepreneurship Agency) is also acknowledged for its support.

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Authors and Affiliations

  1. Department of Mechanical Engineering, KU Leuven, Campus Diepenbeek, Wetenschapspark 27, 3590, Diepenbeek, Belgium

    Kristof Steijvers & Elke Deckers

  2. Flanders Make@KU Leuven, Heverlee, Belgium

    Kristof Steijvers, Claus Claeys, Lucas Van Belle & Elke Deckers

  3. Department of Mechanical Engineering, KU Leuven, Celestijnenlaan 300, Box 2420, 3001, Heverlee, Belgium

    Claus Claeys & Lucas Van Belle

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  1. Kristof Steijvers
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Correspondence to Kristof Steijvers.

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Steijvers, K., Claeys, C., Van Belle, L. et al. Incorporating Manufacturing Process Simulations to Enhance Performance Predictions of Injection Moulded Metamaterials. J. Vib. Eng. Technol. 11, 2617–2629 (2023). https://doi.org/10.1007/s42417-023-01159-1

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