An implicit control-volume finite element method and its time step strategies for injection molding simulation

Abstract An implicit control-volume finite element method was proposed for simulation of injection molding, the time steps were controlled for both flow and thermal simulation by local flow information, and then the computing complexity analysis was conducted. The implicit scheme was based on updating the melt–air interface. The time steps of implicit algorithm were controlled by injection ratio and local mesh information of flow front to achieve “one time step, one element-layer” for filling simulation; the sub-time steps of computing temperatures were calculated for each node according to local courant number, and the thermal simulation was conducted by the filled order of nodes. Both analysis and case studies showed that the computing complexity of flow simulation was second-order of mesh size (nodal number) and one of thermal simulation was 1.5-order. As a result, the computing times and complexity of solving temperature were less than those of solving pressure.

[1]  S. F. Shen,et al.  A finite-element/finite-difference simulation of the injection-molding filling process , 1980 .

[2]  Wen-Bin Young,et al.  Mold filling and cure modeling of RTM and SRIM processes , 1994 .

[3]  R. C. Mcilhenny,et al.  Modeling fountain flow and filling front shape in reaction injection molding , 1993 .

[4]  Jiang Shun-liang,et al.  Approximation of Fountain Effects for Mid-plane Modeling of Injection Molding , 2006 .

[5]  Yong-Taek Im,et al.  Numerical simulation of three-dimensional fiber orientation in short-fiber-reinforced injection-molded parts , 2002 .

[6]  Nitin R. Anturkar.  Petrov-Galerkin finite element analysis for advancing flow front in reaction injection molding , 1995 .

[7]  W. H. Liu,et al.  Numerical simulation and experimental investigation of injection mold filling with melt solidification , 1989 .

[8]  T. Coupez,et al.  A Taylor discontinuous Galerkin method for the thermal solution in 3D mold filling , 1999 .

[9]  Vaughan R Voller,et al.  An algorithm for analysis of polymer filling of molds , 1995 .

[10]  Suresh G. Advani,et al.  Operator splitting scheme for 3-D temperature solution based on 2-D flow approximation , 1995 .

[11]  Vaughan R Voller,et al.  A time-implicit filling algorithm , 1994 .

[12]  Y. K. Shen.  Study on the gas-liquid interface and polymer melt front in gas-assisted injection molding , 1997 .

[13]  Ming-Shyan Huang,et al.  Simulation of injection-compression mold-filling process , 1998 .

[14]  Dequn Li,et al.  Analysis of thermal residual stress in plastic injection molding , 2000 .

[15]  Gene H. Golub,et al.  Matrix computations (3rd ed.) , 1996 .

[16]  James O. Wilkes,et al.  Numerical analysis of injection molding of glass fiber reinforced thermoplastics. Part 2: Fiber orientation , 1997 .

[17]  Kumar K. Tamma,et al.  On a Pure Finite-Element-Based Methodology for Resin Transfer Mold (RTM) Filling Simulations. , 1999 .

[18]  Mahesh Gupta,et al.  Three‐dimensional simulation of microchip encapsulation process , 2000 .

[19]  Yong-Taek Im,et al.  Compressible flow analysis of filling and postfilling in injection molding with phase-change effect , 1997 .

[20]  Wen-Hsien Yang,et al.  Numerical simulation of mold filling in injection molding using a three‐dimensional finite volume approach , 2001 .

[21]  C. J. Hwang,et al.  A full 3D finite element analysis of the powder injection molding filling process including slip phenomena , 2002 .

[22]  Avraam Isayev,et al.  Modeling and experimental study of birefringence in injection molding of semicrystalline polymers , 2005 .

[23]  Florin Ilinca,et al.  Three-dimensional simulation of multi-material injection molding: Application to gas-assisted and co-injection molding , 2003 .

[24]  J. Mcgrath,et al.  Determination of 3D fiber orientation distribution in thermoplastic injection molding , 1995 .

[25]  F. Trochu,et al.  Numerical analysis of the resin transfer molding process by the finite element method , 1993 .

[26]  Yun-Wey Yu,et al.  A hybrid 3D/2D finite element technique for polymer processing operations , 1999 .

[27]  Gene H. Golub,et al.  Matrix computations , 1983 .

[28]  K. D. Fickie,et al.  A Fast Numerical Method for Isothermal Resin Transfer Mold Filling , 1996 .

[29]  B. Friedrichs,et al.  A hybrid numerical technique to model 3-D flow fields in resin transfer molding processes , 1995 .

[30]  J. B. Park,et al.  Finite element analysis modeling of powder injection molding filling process including yield stress and slip phenomena , 1995 .

[31]  van de Fn Frans Vosse,et al.  A 3-D finite element model for gas-assisted injection molding - simulations and experiments , 2001 .

[32]  Yuexin Duan,et al.  An interface-update-based implicit algorithm for mold filling simulation of liquid composite molding , 2006 .

[33]  Tai Hun Kwon,et al.  Coupled analysis of injection molding filling and fiber orientation, including in‐plane velocity gradient effect , 1996 .

[34]  Kumar K. Tamma,et al.  Non-isothermal ‘2-D flow/3-D thermal’ developments encompassing process modelling of composites: flow/thermal/cure formulations and validations , 1999 .

[35]  Jean-Francois Hetu,et al.  3D finite element method for the simulation of the filling stage in injection molding , 1998 .

[36]  Huamin Zhou,et al.  A numerical simulation of the filling stage in injection molding based on a surface model , 2001 .