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

Author(s)

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

• Document type: Journal article
• Source: JOURNAL OF VIBRATION ENGINEERING & TECHNOLOGIES; v. 11, n. 6, p. 13-pg., 2023-10-25.

Abstract

PurposeLocally 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.MethodsThe 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 ConclusionIncorporating injection moulding simulations in structural dynamic modelling clearly improves the eigenfrequency predictions of the manufactured resonators as well as the metamaterial stopband predictions. (AU)

• FAPESP's process: 21/05510-3 - Mass-manufacturable metamaterials with passive and smart inclusions for broadband noise and vibration attenuation performance
• Grantee: Leopoldo Pisanelli Rodrigues de Oliveira
• Support Opportunities: Regular Research Grants