Nanopattern replication of complex structures by plastic injection is a challenge that requires simulations to define the right processing parameters. Previous work managed to simulate replication for single cavities in 2D and 3D, showing high performance requirements of CPU to simulate periodic trenches in 2D. This paper presents two ways to approach the simulation of replication of complex 3D hydrophobic surfaces. The first approach is based on previous CFD Ansys Fluent and compared to FE based CFD Polyflow software for the analysis of laminar flows typical in polymer processing and glass forming as well as other applications. The results showed that Polyflow was able to reduce computing time from 72 h to only 5 min as desired in the project. Furthermore, simulations carried out with Polyflow showed that higher injection and mold temperature lead to better replication of hydrophobicity in agreement with the experiments. Polyflow simulations are proved to be a good tool to define process parameters such as temperature and cycle times for nanopattern replication.
This research studies how the angle and dimensions of a single baffle affect the dynamics of a fluid in a closed rectangular tank under an accelerated harmonic vibration in resonance. A half-filled non-deformable rectangular tank with a single centered submerged baffle has been simulated using ANSYS® FLUENT. The study aims to characterize the effect of changing the baffle’s angle; hence, 10 simulations have been performed: without a baffle, 90∘, 30∘, 60∘, 120∘ and 150∘, either maintaining the baffle’s length or the projected height constant. The computational fluid dynamics (CFD) method using volume of fluid (VOF) and large eddy simulation (LES) are used to predict the movement of the fluid in two dimensions, which have been benchmarked against experimental data with excellent agreement. The motion is sinusoidal in the +X direction, with a frequency of oscillation equal to its first vibration mode. The parameters studied have been the free surface elevation, values at three different points and maximum; the center of gravity’s position, velocity, and acceleration; and the forces against the tank’s walls. It has been found that the 90∘ angle has the most significant damping effect, stabilizing the free-surface elevation, reducing the center of gravity dispersion, and leveling the impacting forces. Smaller angles also tame the sloshing and stabilize it.
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