Modified Method for Simulation of the Filling States at the End of Injection Molding Process

In order to improve the accuracy of numerical simulation for injection molding process, a modified method for outlet condition was introduced. As the feedstock is regarded as incompressible fluid, the filling ratio should be a linear one with respect to time. But there remains a persistent trouble in previous researches that the linearity is not respected when the filling front approaches near the outlet boundary. The problem is caused by lack of adequate treatment on the outlet boundary. To remedy this defect, the present paper deals with the modeling and realization of suitable condition on outlet boundary for solution of the whole filling process. A simple straight channel mold was taken as an example to prove the proposed simulation method. The result shows that this modified method can suppress the distortion phenomenon and can be valid to realize the correct simulation for the filling of incompressible viscous flow at the ending stage. This long-term filling problem was finally solved.

[1]  S. Richardson,et al.  Numerical simulation of the fountain flow problem for viscoelastic fluids , 1995 .

[2]  E. J. Holm,et al.  A unified finite element model for the injection molding process , 1999 .

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

[4]  Jean-Claude Gelin,et al.  Determination of the optimal process parameters in metal injection molding from experiments and numerical modeling , 2003 .

[5]  D. Gao.  Modélisation numérique du remplissage des moules de fonderie par la méthode des éléments finis , 1991 .

[6]  J. Gelin,et al.  Analyses of powder segregation in MIM , 2002 .

[7]  M. Kamal,et al.  The fluid mechanics and heat transfer of injection mold filling of thermoplastic materials , 1976 .

[8]  I. Dag,et al.  Taylor-Galerkin and Taylor-collocation methods for the numerical solutions of Burgers’ equation using B-splines , 2011 .

[9]  M. E. Ryan,et al.  Conformal mapping analysis of infection mold filling , 1980 .

[10]  J. Gelin,et al.  A new explicit simulation for injection molding and its validation , 2009 .

[11]  D. M. Gao,et al.  A finite element simulation of metal flow in moulds , 1990 .

[12]  J. Alcock,et al.  Fabrication of hollow, 3D, micro-scale metallic structures by micro-powder injection moulding , 2012 .

[13]  R. S. Spencer,et al.  Some flow phenomena in the injection molding of polystyrene , 1951 .

[14]  J. Gelin,et al.  Determination of critical and optimal powder loadings for 316L fine stainless steel feedstocks for micro-powder injection molding , 2012 .

[15]  Han Ping Hong,et al.  Fabrication of metal matrix composites by metal injection molding—A review , 2008 .

[16]  J. F. Dijksman,et al.  Non-isothermal flow of a molten polymer in a narrow rectangular cavity , 1982 .

[17]  Asif Usmani,et al.  Efficient mould filling simulation in castings by an explicit finite element method , 1995 .

[18]  M. J. Murphy,et al.  Resin transfer molding process optimization , 2000 .

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

[20]  Andrew N. Hrymak,et al.  Finite element simulation of fountain flow in injection molding , 1986 .

[21]  T. Coupez,et al.  Finite element solution of the 3D mold filling problem for viscous incompressible fluid , 1998 .

[22]  J. Gelin,et al.  Improving mould design and injection parameters in metal injection moulding by accurate 3D finite element simulation , 2002 .