Experimental analysis and numerical modelling of the forming process of polypropylene replicas of micro-cavities using hot embossing

Numerical modelling of the deformation of a polymer using the finite elements method in axisymetrical mode was performed using the LsDyna^® software to describe the filling of micro-cavities during the forming process of the material using the hot embossing. These simulations firstly allow verifying whether the chosen forming process conditions promote or not an optimized filling of the superficial cavities in order to achieve precise replicas which best reproduce the superficial topography of the mould. The simulations were carried out to evaluate the filling of the cavities taking into account the mechanical behaviour of the selected polymer into the model. Moreover, these models were developed to verify the effect of the distribution of the mould cavities on their filling. The influence of the mobility of non deformable rigid plates on the filling of the cavities represents an auxiliary variable. In the approach presented, the compression plates are assumed to be parallel and non deformable, whereas the polymer disk follows a rubbery behaviour around a temperature equal to 140°C. Globally the modelling results are satisfactory for they are rather close to the experimental observations conducted. In summary, the effect of the normal stress as also the distribution of micro-cavities at the mould surface seem to prevail in the case of the forming process by hot embossing.