Details
| Original language | English |
|---|---|
| Article number | 033102 |
| Journal | Physics of fluids |
| Volume | 34 |
| Issue number | 3 |
| Early online date | 9 Mar 2022 |
| Publication status | Published - Mar 2022 |
Abstract
In this paper, we introduce a mesh-free numerical framework using the finite pointset method for the modeling and simulation of injection molding processes. When compared to well-established mesh-based methods, which have been widely applied for these applications, our approach avoids the need for extensive preprocessing and enables accurate treatment of free surfaces and other associated phenomena. To accurately model the polymer injections, we consider a detailed material model, with temperature dependent viscosity and density, while also considering shear thinning behavior with a strain rate dependent viscosity. Our numerical investigations show that injection molding-specific problems such as the modeling of viscous flows and the fountain flow effect can be successfully implemented using our presented framework. For a thorough validation of our proposed model, we compare the simulated flow behavior with injection molding experiments, which are also performed in this work. The experimental setup considers the injection of a polymer melt into a spiral mold. The flow behavior is investigated experimentally at varying melt injection and wall temperature, with different threshold pressures. Our numerical simulations show a good comparison with these experimental results, both qualitatively and quantitatively. We also introduce a correction mechanism to ensure energy conservation, which has often been challenging in mesh-free approaches. This is the first time that the flow behavior in a mesh-free injection molding method has been experimentally validated and successfully applied to the simulation of an actual industrial vehicle component.
ASJC Scopus subject areas
- Engineering(all)
- Computational Mechanics
- Physics and Astronomy(all)
- Condensed Matter Physics
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
- Chemical Engineering(all)
- Fluid Flow and Transfer Processes
Sustainable Development Goals
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In: Physics of fluids, Vol. 34, No. 3, 033102, 03.2022.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Mesh-free simulations of injection molding processes
AU - Veltmaat, Lennart
AU - Mehrens, Felix
AU - Endres, Hans Josef
AU - Kuhnert, Jörg
AU - Suchde, Pratik
N1 - Funding Information: Pratik Suchde would like to acknowledge partial support from the European Union’s Horizon 2020 research and innovation program under the Marie Sklodowska-Curie Actions Grant Agreement No. 892761 “SURFING.”
PY - 2022/3
Y1 - 2022/3
N2 - In this paper, we introduce a mesh-free numerical framework using the finite pointset method for the modeling and simulation of injection molding processes. When compared to well-established mesh-based methods, which have been widely applied for these applications, our approach avoids the need for extensive preprocessing and enables accurate treatment of free surfaces and other associated phenomena. To accurately model the polymer injections, we consider a detailed material model, with temperature dependent viscosity and density, while also considering shear thinning behavior with a strain rate dependent viscosity. Our numerical investigations show that injection molding-specific problems such as the modeling of viscous flows and the fountain flow effect can be successfully implemented using our presented framework. For a thorough validation of our proposed model, we compare the simulated flow behavior with injection molding experiments, which are also performed in this work. The experimental setup considers the injection of a polymer melt into a spiral mold. The flow behavior is investigated experimentally at varying melt injection and wall temperature, with different threshold pressures. Our numerical simulations show a good comparison with these experimental results, both qualitatively and quantitatively. We also introduce a correction mechanism to ensure energy conservation, which has often been challenging in mesh-free approaches. This is the first time that the flow behavior in a mesh-free injection molding method has been experimentally validated and successfully applied to the simulation of an actual industrial vehicle component.
AB - In this paper, we introduce a mesh-free numerical framework using the finite pointset method for the modeling and simulation of injection molding processes. When compared to well-established mesh-based methods, which have been widely applied for these applications, our approach avoids the need for extensive preprocessing and enables accurate treatment of free surfaces and other associated phenomena. To accurately model the polymer injections, we consider a detailed material model, with temperature dependent viscosity and density, while also considering shear thinning behavior with a strain rate dependent viscosity. Our numerical investigations show that injection molding-specific problems such as the modeling of viscous flows and the fountain flow effect can be successfully implemented using our presented framework. For a thorough validation of our proposed model, we compare the simulated flow behavior with injection molding experiments, which are also performed in this work. The experimental setup considers the injection of a polymer melt into a spiral mold. The flow behavior is investigated experimentally at varying melt injection and wall temperature, with different threshold pressures. Our numerical simulations show a good comparison with these experimental results, both qualitatively and quantitatively. We also introduce a correction mechanism to ensure energy conservation, which has often been challenging in mesh-free approaches. This is the first time that the flow behavior in a mesh-free injection molding method has been experimentally validated and successfully applied to the simulation of an actual industrial vehicle component.
UR - http://www.scopus.com/inward/record.url?scp=85126591269&partnerID=8YFLogxK
U2 - 10.1063/5.0085049
DO - 10.1063/5.0085049
M3 - Article
AN - SCOPUS:85126591269
VL - 34
JO - Physics of fluids
JF - Physics of fluids
SN - 1070-6631
IS - 3
M1 - 033102
ER -