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

作　　者：Xin Zhuang Jie Ouyang Chuntao Jiang Qingsheng Liu 

机构地区：[1]Department of Applied Mathematics, Northwestern Polytechnical University

出　　处：《Chinese Journal of Chemical Engineering》2016年第7期832-842,共11页中国化学工程学报（英文版）

基　　金：Supported by the National Basic Research Program of China(2012CB025903);the National Natural Science Foundation of China(91434201,11402210)

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 flow in melt filling process, where the Cross-WLF model is applied to characterize the rheological behav- ior 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 exten- sion technique is adopted to deal with 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 orediction for injection molding process.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 flow in melt filling process, where the Cross-WLF model 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 deal with 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 moldingNon-isothermalFinite voIume/SIMPLEC methodDomain extension techniqueHigh resolution level set method 

分 类 号：TQ320.66[化学工程—合成树脂塑料工业]