Numerical Approach for the Assessment of Micro-Textured Walls Effects on Rubber Injection Moulding.

Micro-surface texturing of elastomeric seals is a validated method to improve the friction and wear characteristics of the seals. In this study, the injection process of high-viscosity elastomeric materials in moulds with wall microprotusions is evaluated. To this end, a novel CFD methodology is developed and implemented in OpenFOAM to address rubber flow behaviour at both microscale and macroscale. The first approach allows analyzing the flow perturbation induced by a particular surface texture and generate results to calculate an equivalent wall shear stress that is introduced into the macroscale case through reduced order modelling. The methodology is applied to simulate rubber injection in textured moulds in an academic case (straight pipe) and a real case (D-ring seal mould). In both cases, it is shown that textured walls do not increase the injection pressure and therefore the manufacturing process is not adversely affected.

Demoulding process assessment of elastomers in micro-textured moulds.

Background: Micro-texturing is an increasingly used technique that aims at improving the functional behaviour of components during their useful life, and it is applied in different industrial manufacturing processes for different purposes, such as reducing friction on dynamic rubber seals for pneumatic equipment, among others. Micro-texturing is produced on polymer components by transfer from the mould and might critically increase the adhesion and friction between the moulded rubber part with the mould, provoking issues during demoulding, both on the mould itself and on the rubber part. The mould design, the coating release agent applied to the mould surface, and the operational parameters of the moulding/demoulding process, are fundamental aspects to avoid problems and guarantee a correct texture transfer during the demoulding process. Methods: In this work, the lack of knowledge about demoulding processes was addressed with an in-house test rig and a robust experimental procedure to measure demoulding forces (DFs) as well as the final quality of the moulded part, between thermoset polymers and moulds. After the characterization of several Sol-Gel coating formulations (inorganic; hybrid) the influence of several parameters was analysed experimentally, i.e.: Sol-Gel efficiency, texture effects, pattern geometry, roughness and material compound. Results: The results obtained from the experimental studies revealed that texture depth is the most critical geometrical parameter, showing high scatter among the selected compounds. Finally, the experimental results were used to compute a model through reduced order modelling (ROM) technique for the prediction of DFs. Conclusions: The characterization of DFs in a laboratory, with a specific device operated by a universal testing machine (UTM), provided valuable information that allows a fast and optimized introduction of texturing in rubber components. Selection of a novel Sol-Gel coating and the use of the ROM technique contributed to speed up implementation for mass production.

Mechanical response of the herniated human abdomen to the placement of different prostheses.

This paper describes a method designed to model the repaired herniated human abdomen just after surgery and examine its static mechanical response to the maximum intra-abdominal pressure provoked by a physiological movement (standing cough). The model is based on the real geometry of the human abdomen bearing a large incisional hernia with several anatomical structures differentiated by MRI. To analyze the outcome of hernia repair, the surgical procedure was simulated by modeling a prosthesis placed over the hernia. Three surgical meshes with different mechanical properties were considered: an isotropic heavy-weight mesh (Surgipro®), a slightly anisotropic light-weight mesh (Optilene®), and a highly anisotropic medium-weight mesh (Infinit®). Our findings confirm that anisotropic implants need to be positioned such that the most compliant axis of the mesh coincides with the craneo-caudal direction of the body.

The long-term behavior of lightweight and heavyweight meshes used to repair abdominal wall defects is determined by the host tissue repair process provoked by the mesh.

BACKGROUND: Although heavyweight (HW) or lightweight (LW) polypropylene (PP) meshes are widely used for hernia repair, other alternatives have recently appeared. They have the same large-pore structure yet are composed of polytetrafluoroethylene (PTFE). This study compares the long-term (3 and 6 months) behavior of meshes of different pore size (HW compared with LW) and composition (PP compared with PTFE). METHODS: Partial defects were created in the lateral wall of the abdomen in New Zealand White rabbits and then repaired by the use of a HW or LW PP mesh or a new monofilament, large-pore PTFE mesh (Infinit). At 90 and 180 days after implantation, tissue incorporation, gene and protein expression of neocollagens (reverse transcription-polymerase chain reaction/immunofluorescence), macrophage response (immunohistochemistry), and biomechanical strength were determined. Shrinkage was measured at 90 days. RESULTS: All three meshes induced good host tissue ingrowth, yet the macrophage response was significantly greater in the PTFE implants (P < .05). Collagen 1/3 mRNA levels failed to vary at 90 days yet in the longer term, the LW meshes showed the reduced genetic expression of both collagens (P < .05) accompanied by increased neocollagen deposition, indicating more efficient mRNA translation. After 90-180 days of implant, tensile strengths and elastic modulus values were similar for all 3 implants (P > .05). CONCLUSION: Host collagen deposition is mesh pore size dependent whereas the macrophage response induced is composition dependent with a greater response shown by PTFE. In the long term, macroporous meshes show comparable biomechanical behavior regardless of their pore size or composition.