New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method

doi:10.1016/j.cjche.2016.04.014

›› 2016, Vol. 24 ›› Issue (7): 832-842.DOI: 10.1016/j.cjche.2016.04.014

• Fluid Dynamics and Transport Phenomena • 上一篇下一篇

New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method

Xin Zhuang, Jie Ouyang, Chuntao Jiang, Qingsheng Liu

Department of Applied Mathematics, Northwestern Polytechnical University, Xi'an 710129, China

收稿日期:2015-05-05 修回日期:2016-03-30 出版日期:2016-07-28 发布日期:2016-08-17
通讯作者: Jie Ouyang
基金资助:
Supported by the National Basic Research Program of China (2012CB025903), the National Natural Science Foundation of China (91434201, 11402210).

New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method

Xin Zhuang, Jie Ouyang, Chuntao Jiang, Qingsheng Liu

Department of Applied Mathematics, Northwestern Polytechnical University, Xi'an 710129, China

Received:2015-05-05 Revised:2016-03-30 Online:2016-07-28 Published:2016-08-17
Supported by:
Supported by the National Basic Research Program of China (2012CB025903), the National Natural Science Foundation of China (91434201, 11402210).

摘要/Abstract

摘要： The simulation of three-dimensional (3D) non-isothermal, non-Newtonian fluid filling process is an extremely difficult task and remains a challenging problem, which includes polymer melt flow with free surface coupled with transient heat transfer. This paper presents a full 3D non-isothermal two-phase flow model to predict the complex flowinmelt filling process,where the Cross-WLFmodel is applied to characterize the rheological behavior of polymer melt. The governing equations are solved using finite volume method with SIMPLEC algorithm on collocated grids and the melt front is accurately captured by a high resolution level set method. A domain extension technique is adopted to dealwith the complex cavities, which greatly reduces the computational burden. To verify the validity of the developed 3D approach, the melts filling processes in two thin rectangular cavities (one of them with a cylindrical insert) are simulated. The predicted melt front interfaces are in good agreement with the experiment and commercial software prediction. For a case with a rather complex cavity, the dynamic filling process in a hemispherical shell is successfully simulated. All of the numerical results show that the developed numerical procedure can provide a reasonable prediction for injection molding process.

关键词: Injection molding, Non-isothermal, Finite volume/SIMPLEC method, Domain extension technique, High resolution level set method

Abstract: The simulation of three-dimensional (3D) non-isothermal, non-Newtonian fluid filling process is an extremely difficult task and remains a challenging problem, which includes polymer melt flow with free surface coupled with transient heat transfer. This paper presents a full 3D non-isothermal two-phase flow model to predict the complex flowinmelt filling process,where the Cross-WLFmodel is applied to characterize the rheological behavior of polymer melt. The governing equations are solved using finite volume method with SIMPLEC algorithm on collocated grids and the melt front is accurately captured by a high resolution level set method. A domain extension technique is adopted to dealwith the complex cavities, which greatly reduces the computational burden. To verify the validity of the developed 3D approach, the melts filling processes in two thin rectangular cavities (one of them with a cylindrical insert) are simulated. The predicted melt front interfaces are in good agreement with the experiment and commercial software prediction. For a case with a rather complex cavity, the dynamic filling process in a hemispherical shell is successfully simulated. All of the numerical results show that the developed numerical procedure can provide a reasonable prediction for injection molding process.

Key words: Injection molding, Non-isothermal, Finite volume/SIMPLEC method, Domain extension technique, High resolution level set method

Xin Zhuang, Jie Ouyang, Chuntao Jiang, Qingsheng Liu. New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method[J]. , 2016, 24(7): 832-842.

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New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method

New approach to develop a 3D non-isothermal computational framework for injection molding process based on level set method

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