As large components of fiber reinforced composite materials are being more frequently produced by Resin Transfer Molding (RTM), a computer simulation of the injection process can help the mold designer to accomplish three important tasks: (1) to ensure a complete filling of the mold through adequate positioning of the injection ports and of the air vents; (2) to verify the integrity of the mold during the filling process through knowledge of the pressure distribution; and (3) to optimize the production cycle using information about the filling time. The resin impregnation is usually modeled as a flow through a porous medium. It is governed by Darcy's law, which states that the flow rate is proportional to the pressure gradient. In our model, Darcy equation is solved at each time step inside the saturated part of the mold using nonconforming finite elements. This method was chosen because the approximated flow rates, contrary to conforming finite elements, satisfy locally the important physical condition of resin conservation across inter-element boundaries. This permits simplification of the numerical procedure. It is no longer necessary to resort to a control volume approach to move the flow front forward. The resin pressure distribution and the resin front positions are obtained by the computer simulation and calculated results for selected mold geometries are compared with experimental observations. Molds with inserts, multiple injection ports, and the case of anisotropic preforms can be analyzed by the computer program.Sons, Inc.-

During the molding of industrial parts using injection molding, the molten polymer flow through converging and diverging sections as well as in areas presenting thickness and flow direction changes. A good understanding of the flow behavior and thermal history is important in order to optimize the part design and molding conditions. This is particularly true in the case of automotive and electronic applications where the coupled phenomena of fluid flow and heat transfer determine to a large extent the final properties of the part. This paper presents a 3D finite element model capable of predicting the velocity, pressure, and temperature fields, as well as the position of the flow fronts. The velocity and pressure fields are governed by the generalized Stokes equations. The fluid behavior is predicted through the Carreau Law and Arrhenius constitutive models. These equations are solved using a Galerkin formulation. A mixed formulation is used to satisfy the continuity equation. The tracking of the flow front is modeled by using a pseudo‐concentration method and the model equations are solved using a Petrov‐Galerkin formulation. The validity of the method has been tested through the analysis of the flow in simple geometries. Its practical relevance has been proven through the analysis of an industrial part.

SUMMARYNumerical tools for simulating the casting process are employed in an increasing manner by foundry engineers in order to understand and improve casting techniques. The correct simulation of metal flow and temperature profiles during filling is an important part of an overall numerical simulation kit which includes solidification and residual stress evaluations.In this study, we develop a two-dimensional finite element model for studying metal flow and temperature fields during filling of mould cavities. A proper choice of turbulent/laminar model, correct tracking of metal free surface and evaluation of temperature to include metal-air-sand interaction are some of the essential features of the model.

Injection molded parts often show several types of surface defect. It has been hypothesized that wall slip is associated with some of these defects. Wall slip of molten plastics has been observed above a certain critical shear stress in rheological measurements. The objectives of the proposed research were to analyze the occurrence of flow marks during the injection molding of linear polyethylene and evaluate its possible relation to wall slip. Various variables were studied in terms of their influence on flow mark formation: mold thickness, mold temperature, melt temperature, gate, injection speed and TeflonTM and silicone oil coatings. It was found that injection speed is the controlling factor for the generation of flow marks during injection molding of the linear polyethylenes studied. Since one of the resin studied had shown no tendency to slip in capillary flow experiments, and since a Teflon TM coating on the mold walls did not affect the occurrence of flow marks, we conclude that there is no relationship between wall slip and the generation of flow marks. Microscopic observation of molded surfaces suggests instead that flow marks result from the filamentaton and stretching of semi-solidified material in the neighborhood of the three-phase contact line.

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