Metal Wire Microextrusion Using MR Fluid for Stable 3D Micro-Parts
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Solution Overview
Problem
In microextrusion, metal alloy wires with superplastic deformation behavior tend to deform or break during feeding, posing challenges in raw material handling and limiting the production of complex micro-parts with high mechanical properties and homogeneity.
Innovation Solution
A method and apparatus that control the molding temperature of metal wires within the supercooled liquid or high temperature deformation section, combined with the use of magnetorheological fluid to facilitate the feeding of metal wires without deformation or breakage, enabling the production of three-dimensional micro-parts with excellent mechanical properties and material homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal alloy wire with superplastic deformation behavior is used for microextrusion, then excellent mechanical properties and material homogeneity are achieved, but the wire deforms or breaks during feeding
Solution Approach 1:
The patent controls the molding temperature within specific ranges: in the supercooled liquid temperature section (between melting point and crystallization temperature) for amorphous metals, or in the high temperature deformation section for crystalline metals. This parameter control enables the metal wire to be fed without deformation or breakage while maintaining excellent mechanical properties and material homogeneity.
Solution Approach 2:
The patent introduces a magnetorheological fluid as an intermediary substance to facilitate the feeding of metal wires. The MR fluid enables the wire to be fed smoothly without direct mechanical contact that would cause deformation or breakage, thereby improving feeding reliability while preserving the wire's mechanical properties.
2Manufacturing precision
If conventional manufacturing methods are used for micro-parts, then simplicity is maintained, but parts with size of several tens of micrometers to several millimeters cannot be manufactured
Solution Approach 1:
The patent employs microextrusion technology with controlled temperature parameters to manufacture three-dimensional micro-parts with sizes ranging from several tens of micrometers to several millimeters. This enables the production of complex micro-geometries that cannot be achieved by conventional manufacturing methods.
3Strength
If amorphous metal wire is used for microextrusion, then high tensile strength and corrosion resistance are achieved, but the wire deforms or breaks during feeding
Solution Approach 1:
The patent controls the molding temperature to be within the supercooled liquid temperature section (between melting point and crystallization temperature) for amorphous metals. This temperature control allows the amorphous metal wire to be fed without deformation or breakage, preserving its high tensile strength and corrosion resistance properties.
Solution Approach 2:
The magnetorheological fluid serves as a mediator that enables smooth feeding of amorphous metal wires by reducing direct mechanical contact and friction, thereby preventing deformation and breakage during the feeding process while maintaining the wire's inherent high strength properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the mass production of micro-molded products with sizes ranging from tens of micrometers to several millimeters, suitable for applications in microrobots, micro-system parts, and biomedical devices, while reducing manufacturing costs and complexity.
Implementation Method 1
a magnetorheological fluid (MR fluid) is used when a micro-wire is fed during microextrusion, whereby the wire is fed without undergoing deformation or breakage
Implementation Method 2
a molding temperature is controlled to be included in a supercooled liquid temperature section or a specific high temperature deformation temperature section of the metal wire
Implementation Method 3
The superplastic deformation of materials is a phenomenon in which deformation stability is increased at a specific deformation condition (temperature, strain rate, and the like), thus exhibiting a high elongation of several hundred percent or more
Data Source
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Figure 2
Figure 3~4a
AI summary
The present invention relates to a method and an apparatus for manufacturing a micro-molded product by using a metal wire. The method includes: feeding the metal wire to a molding device by using a magnetorheological fluid (MR fluid); and manufacturing the metal wire into a molded product. According to the present invention, the method and the apparatus for manufacturing the micro-molded product can manufacture three-dimensional micro-parts having a size of several tens of micrometers to several millimeters and thus mass production thereof is possible, thus finding application in microrobots, micro-system parts, biomedical system parts, electronic device parts, and the like.