Simulation of thin-walled injection molded magnets

Injection molded magnets offer significant advantages in production cost and freedom of design compared to sintered magnets. The magnetic properties of the molded magnets are influenced by complex and interdependent factors derived from process settings as well as magnetic and rheological material properties. Simulation of the resulting injection molded magnets is therefore very difficult. Existing approaches suffer from reduced accuracy for thin-walled parts since an inhomogeneous distribution of melt temperatures during filling is not taken into account. In this paper, a new simulation approach is presented that includes these influences. The new approach is first described step by step. The measurement of required material properties is presented and the results are discussed for an exemplary material. Simulations of a thin-walled injection molded plate with a multipolar magnetization structure are then performed using an existing as well as the new approach. The results for this part are finally compared in order to determine the new simulation approach´s feasibility.