Development of In-Mold Assembly Methods for Producing Mesoscale Revolute Joints

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dc.contributor.advisorGupta, Satyandra Ken_US
dc.contributor.authorAnanthanarayanan, Arvinden_US
dc.contributor.departmentMechanical Engineeringen_US
dc.contributor.publisherDigital Repository at the University of Marylanden_US
dc.contributor.publisherUniversity of Maryland (College Park, Md.)en_US
dc.date.accessioned2009-07-03T05:36:41Z
dc.date.available2009-07-03T05:36:41Z
dc.date.issued2009en_US
dc.description.abstractIn-mold assembly is a promising process for producing articulated joints. It utilizes injection molding to automate assembly operations, which may otherwise require high labor times for production. Since injection molding is a high throughput process, in-mold assembly holds considerable promise in bulk production of assembled parts. However, current in-mold assembly methods cannot be used for manufacturing in-mold assembled products at the mesoscale. This is because the process changes considerably when the sizes of the molded parts are reduced. The premolded component in a mesoscale joint consists of miniature features. Hence, when a high temperature, high pressure polymer melt is injected on top of it, it is susceptible to plastic deformation. Due to presence of a mesoscale premolded component which is susceptible to deformation, traditional shrinkage models alone can not be used to characterize and control the clearances. This dissertation identifies and addresses issues pertaining to in-mold assembly of revolute joints at the mesoscale. First, this dissertation identifies defect modes which are unique to in-mold assembly at the mesoscale. Then it develops mold design templates which can be used for manufacturing in-mold assembled mesoscale revolute joints. Further, issues related to the deformation of the mesoscale premolded component are identified. Two novel mold design solutions to realize mesoscale in-mold assembled revolute joints are presented. The first involves use of mold inserts to constrain the premolded component to inhibit its deformation. The second involves use of a bi-directional flow of the polymer melt over the premolded component to balance the deforming forces experienced by it. Finally, methods to predict and control clearances that would be obtained in mesoscale in-mold assembled revolute joints are presented. To demonstrate the utility of the tools built as part of this research effort, a case study of a miniature robotic application built using mesoscale in-mold assembly methods is presented. This dissertation provides a new approach for manufacturing mesoscale assemblies which can lead to reduction in product cost and create several new product possibilities.en_US
dc.format.extent10801582 bytes
dc.format.mimetypeapplication/pdf
dc.identifier.urihttp://hdl.handle.net/1903/9318
dc.language.isoen_US
dc.subject.pqcontrolledEngineering, Mechanicalen_US
dc.subject.pquncontrolledAutomated Assemblyen_US
dc.subject.pquncontrolledIn-mold assemblyen_US
dc.subject.pquncontrolledInjection Moldingen_US
dc.subject.pquncontrolledInsert Moldingen_US
dc.subject.pquncontrolledNon-linear structural modelingen_US
dc.titleDevelopment of In-Mold Assembly Methods for Producing Mesoscale Revolute Jointsen_US
dc.typeDissertationen_US

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