Two‐dimensional non‐Newtonian injection molding with a new control volume FEM/volume of fluid method

Salinas, Carlos; Vasco, Diego A.; Moraga, Nelson O.

doi:10.1002/fld.3723

Cited by 6 publications

(4 citation statements)

References 29 publications

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“…According to the rheological theory, the viscosity of non-Newtonian fluid will be affected by the velocity gradient. We take the power-law model [26,27] to describe a nonlinear relation between shear stress and the rate of deformation. e strain rate tensor is denoted as d � (∇u + (∇u) T )/2, and its magnitude is c �…”

Section: Power-law Modelmentioning

confidence: 99%

The Finite Element Numerical Investigation of Free Surface Newtonian and Non-Newtonian Fluid Flows in the Rectangular Tanks

Gao

2020

Mathematical Problems in Engineering

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In this paper, we develop a new computational framework to investigate the sloshing free surface flow of Newtonian and non-Newtonian fluids in the rectangular tanks. We simulate the flow via a two-phase model and employ the fixed unstructured mesh in the computation to avoid the mesh distortion and reconstruction. As for the solution of Navier–Stokes equation, we utilize the SUPG finite element method based on the splitting scheme. The same order interpolation functions are then used for velocity and pressure. Moreover, the moving interface is captured via the concise level set method. We take advantage of the implicit discontinuous Galerkin method to handle the solution of level set and its reinitialization equations. A mass correction technique is also added to ensure the mass conservation property. The dam break-free surface flow is simulated firstly to demonstrate the validity of our mathematical model. In addition, the sloshing Newtonian fluid in the tank with flat and rough bottoms is considered to illustrate the feasibility and robustness of our computational scheme. Finally, the development of free surface for non-Newtonian fluid is also studied in the two tanks, and the influence of power-law index on the sloshing fluid flow is analyzed.

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Section: Power-law Modelmentioning

confidence: 99%

The Finite Element Numerical Investigation of Free Surface Newtonian and Non-Newtonian Fluid Flows in the Rectangular Tanks

Gao

2020

Mathematical Problems in Engineering

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“…The flow models for simulating the mold filling process in the early years have been reviewed detailedly by Cardozo. 1 There are also some other reports [2][3][4][5][6][7][8][9] about simulating the mold filling process in the past 30 years. However, the abovementioned reports main focus the evolution of melt front interface and viscosity effect of polymer melt, the elastic characteristics have not been taken into account.…”

Section: Introductionmentioning

confidence: 99%

Macroscopic and mesoscopic simulation of polystyrene melt in the filling process of injection molding

Liu

Jiang

2023

J of Applied Polymer Sci

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In this article, a fluid flow and heat transfer model which consist of the mass, momentum, and energy conservation equations together with the level set equation and Rolie‐Poly constitution equation is proposed and applied to simulate the rheological behaviors of viscoelastic polystyrene melt in the filling process of injection molding. The macroscopic velocity, pressure, temperature, stress, and mesoscopic molecular conformation of polystyrene melt are shown and analyzed detailedly during the mold filling process. The single‐mode Rolie‐Poly model is employed to describe the stress–strain relationship of polystyrene melt, and the level set method is used to capture the evolution of melt front interface. The governing equations for polymer melt are discretized by the finite volume method on collocated mesh, and solved by the SIMPLE algorithm. Numerical simulations have been implemented based on rectangular cavities with different gate locations, and rectangular and circular inserts. Numerical results indicate that the gate locations, gate numbers, insert size and shape are major factors that affect the rheological behaviors of polystyrene melt in the filling stage of injection molding, and polymer chains experienced higher shear and extension effects in the regions near to mold walls and obstacle. In addition, the length and position of weld lines are discussed in the current study.

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“…As for the numerical simulation of the polymer filling process, it mainly involves the solution of Navier‐Stokes (N‐S) equations, the description of the viscoelastic behaviour of the polymer melt, and the capturing of the interface front in the irregular cavity. The finite element method (FEM) has been one of the most popular methods to deal with the two‐phase flow in the filling process. In 2008, Li et al simulated the polymer injection molding process using the adaptive coupled arbitrary Lagrangian‐Eulerian finite element and meshfree method.…”

Section: Introductionmentioning

confidence: 99%

“…However, in order to simplify the problem, they only considered the Newtonian fluid. In 2013, Salinas et al employed a new control volume FEM/volume of fluid method to model the non‐Newtonian filling process. However, they utilized the power law equation to represent the non‐Newtonian fluid, which is not appropriate to describe the rheological behaviour of the viscoelastic polymer.…”

Section: Introductionmentioning

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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Two‐dimensional non‐Newtonian injection molding with a new control volume FEM/volume of fluid method

Cited by 6 publications

References 29 publications

The Finite Element Numerical Investigation of Free Surface Newtonian and Non-Newtonian Fluid Flows in the Rectangular Tanks

The Finite Element Numerical Investigation of Free Surface Newtonian and Non-Newtonian Fluid Flows in the Rectangular Tanks

Macroscopic and mesoscopic simulation of polystyrene melt in the filling process of injection molding

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

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