Numerical simulation of the fountain flow instability in injection molding

Baltussen, Mghm Michiel; Hulsen, MA Martien; Peters, Gwm Gerrit

doi:10.1016/j.jnnfm.2010.03.001

Cited by 32 publications

(17 citation statements)

References 44 publications

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“…The surface tension force is first computed at the centroids of the front elements using a Table 1 Specification of the parameters F; S and s in Eq. (3).…”

Section: Front-tracking Methodsmentioning

confidence: 99%

“…More recently various one-field formulations have been employed to perform direct numerical simulations of interfacial viscoelastic flows. Examples include the level-set [3,45], the volume of fluid (VOF) [14,23,25], marker and cell [43,53,54], phase-field [8,62,67], the conservative semi-Lagrangian advection scheme of constrained interpolation profile method with rational function (CIP-CSLR) [21] and the front-tracking methods [17,18,48]. In addition, versions of the arbitrary Lagrangian-Eulerian (ALE) [15,28,59,63,64] and the Lagrangian [47,61] methods have been also employed.…”

Section: Introductionmentioning

confidence: 99%

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A front-tracking method for computational modeling of viscoelastic two-phase flow systems

Izbassarov

Muradoğlu

2015

Journal of Non-Newtonian Fluid Mechanics

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“…The surface tension force is first computed at the centroids of the front elements using a Table 1 Specification of the parameters F; S and s in Eq. (3).…”

Section: Front-tracking Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A front-tracking method for computational modeling of viscoelastic two-phase flow systems

Izbassarov

Muradoğlu

2015

Journal of Non-Newtonian Fluid Mechanics

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“…Figure shows the velocity vectors in the melt region at t = 1.0 on Mesh2. The phenomenon of the fountain flow, which means that the polymer melt reaches the interface front from the middle region and travels towards the walls, can be observed.…”

Section: Simulation Results and Discussionmentioning

confidence: 99%

Numerical simulation of polymer filling process by a combined finite element/discontinuous Galerkin/level set method

2018

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The filling process in injection molding involves polymer melt and air with large density/viscosity ratios and the transient free surface. It is treated as a challenging viscoelastic-Newtonian two-phase flow problem especially on irregular domains. In this paper, the complex filling process for the irregular cavity is simulated using a combined finite element/discontinuous Galerkin/level set method with application to the socket with five inserts, which is rarely investigated. The rheological behaviour of the viscoelastic fluid is predicted according to the eXtended Pom-Pom (XPP) constitutive model. The level set method proposed from prior literature is utilized to capture the moving interface because of its simplicity and efficiency. The hybrid continuous and discontinuous Galerkin method is utilized to solve the viscoelastic incompressible Navier-Stokes equations. The second order Runge Kutta discontinuous Galerkin (RKDG) method is employed to deal with the XPP constitutive equation and the level set equation due to their hyperbolic natures. This combined algorithm is convenient to cope with the irregular cavity and avoid any stabilization terms. We first investigate the filling process of the rectangular cavity without and with a diamond insert and compare with other numerical and experimental results to illustrate the validity of the coupled method. Moreover, the cavity of the socket with five inserts is considered an application case. We analyze the influences of the inlet velocity and elasticity on physical quantities such as stresses, stretch, etc. The simulation results could provide some numerical predictions for the polymer industry.

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“…In the field of simulation and multiobjective optimization research, Baltussen et al [16] used numerical simulation to study the viscoelastic flow front instability and developed a two-phase viscoelastic model in two dimensions which predicts a fountain flow instability and is able to monitor this instability in the full nonlinear regime. Kanagalakshmi et al [17] proposed a multimodel-based proportional integral derivative (PID) control scheme in real-time and the simulation studies of the PID, fuzzy, and adaptive neurofuzzy inference system (ANFIS) control schemes, which mainly contributes to the barrel temperature control.…”

Section: Introductionmentioning

confidence: 99%

Energy-Efficient Enhancement for Viscoelastic Injection Rheomolding Using Hierarchy Orthogonal Optimization

Wang

Zhang

2018

Mathematical Problems in Engineering

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The viscoelastic injection molding involves multidisciplinary thermoplastic rheomolding parameters which is a complex mathematical problem. Particularly for rheomolding of complex parts with thin-walled structure, boss, and grooves, the increasing higher requirements on energy efficiency and rheomolding quality are put forward. Therefore, an energy-efficient enhancement method for viscoelastic injection molding using hierarchy orthogonal optimization (HOO) is proposed. Based on the thermoplastic rheomolding theory and considering the viscoelastic effects in injection molding, a set of partial differential equations (PDE) describing the physical coupling behavior of the mold-melt-injection molding machine is established. The fuzzy sliding mode control (FSMC) is used to reduce the energy consumption in the control system of the injection molding machine's clamping force. Then, the HOO model of viscoelastic injection rheomolding is built in terms of thermoplastic rheomolding parameters and injection machine parameters. In initial hierarchy, through Taguchi orthogonal experiment and Analysis of Variance (ANOVA), the amount of gate, melt temperature, mold temperature, and packing pressure are extracted as the significant influence parameters. In periodical hierarchy, the multiobjective optimization model takes the forming time, warping deformation, and energy consumption of injection molding as the multiple objectives. The NSGA-II (Nondominated Sorting Genetic Algorithm II) optimization is employed to obtain the optimal solution through the global Pareto front. In ultimate hierarchy, three candidate schemes are compared on multiple objectives to determine the final energy-efficient enhancement scheme. A typical temperature controller part is analyzed and the energy consumption of injection molding is reduced by 41.85%. Through the physical experiment of injection process, the proposed method is further verified.

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Numerical simulation of the fountain flow instability in injection molding

Cited by 32 publications

References 44 publications

A front-tracking method for computational modeling of viscoelastic two-phase flow systems

A front-tracking method for computational modeling of viscoelastic two-phase flow systems

Numerical simulation of polymer filling process by a combined finite element/discontinuous Galerkin/level set method

Energy-Efficient Enhancement for Viscoelastic Injection Rheomolding Using Hierarchy Orthogonal Optimization

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