CFD-Simulation der Kunststoffplastifizierung in einem Extruder mit durchgehend genutetem Zylinder und Barriereschnecke

Karrenberg, Gregor

doi:10.3139/o999.04032016

Cited by 5 publications

(5 citation statements)

References 12 publications

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“…Menges et al [97] modified this model to incorporate the WLF temperature shift factor α T . The equation for the modified Carreau model, also known as the Carreau-WLF model, is described in Equation ( 49) [98].…”

Section: Carreau Modelmentioning

confidence: 99%

Approaches for Numerical Modeling and Simulation of the Filling Phase in Injection Molding: A Review

Baum,

Anders,

Reinicke

2023

Polymers

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Injection molding is a multiphase process that requires accurate simulation of the filling phase. This is a key element in predicting the complete injection molding cycle. The filling phase presents a complex set of challenges, including migrating melt fronts, multi-phase flow, non-Newtonian fluid dynamics, and intertwined heat transfer. Evolving from 1D to 2D, 2.5D, and 3D techniques, filling simulation research has adapted to capture the intricacies of injection-molded parts. However, the need for accuracy in the characterization of the rheological properties of polymers during filling is still of paramount importance. In order to systematically categorize the numerical methods used to simulate the filling phase of injection molding, this review paper provides a comprehensive summary. Particular emphasis is given to the complex interaction of multiple geometric parameters that significantly influence the dynamic evolution of the filling process. In addition, a spectrum of rheological models is thoroughly and exhaustively explored in the manuscript. These models serve as basic mathematical constructs to help describe the complex viscous behavior of polymers during the filling phase. These models cover a spectrum of complexity and include widely recognized formulations such as the Power-Law, second-order, Herschel–Bulkley, Carreau, Bird–Carreau, and Cross models. The paper presents their implementation to include the temperature-dependent influence on viscosity. In this context, the extensions of these models are explained in detail. These extensions are designed to take into account the dynamic viscosity changes caused by the different thermal conditions during the filling process. An important contribution of this study is the systematic classification of these models. This categorization encompasses both academic research and practical integration into commercial software frameworks. In addition to the theoretical importance of these models, their practical value in overcoming challenges in the field of injection molding is emphasized. By systematically outlining these models within a structured framework, this classification promotes a comprehensive understanding of their intrinsic characteristics and relevance in different scenarios.

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Section: Carreau Modelmentioning

confidence: 99%

Approaches for Numerical Modeling and Simulation of the Filling Phase in Injection Molding: A Review

Baum,

Anders,

Reinicke

2023

Polymers

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“…Carreau-WLF model is used to determine the influence of temperature and shear rate on melt viscosity (Equation ( 1)) [64][65][66].…”

Section: Quality Features and Input Parameters Selection: Design Of E...mentioning

confidence: 99%

Predictive Methodology for Quality Assessment in Injection Molding Comparing Linear Regression and Neural Networks

Fernández,

Clavería,

Pina

et al. 2023

Polymers

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The use of recycled polypropylene in industry to reduce environmental impact is increasing. Design for manufacturing and process simulation is a key stage in the development of plastic parts. Traditionally, a trial-and-error methodology is followed to eliminate uncertainties regarding geometry and process. A new proposal is presented, combining simulation with the design of experiments and creating prediction models for seven different process and part quality output features. These models are used to optimize the design without developing additional time-consuming simulations. The study aims to compare the precision and correlation of these models. The methods used are linear regression and artificial neural network (ANN) fitting. A wide range of eight injection parameters and geometry variations are used as inputs. The predictability of nonlinear behavior and compensatory effects due to the complex relationships between this wide set of parameter combinations is analyzed further in the state of the art. Results show that only Back Propagation Neural Networks (BPNN) are suitable for correlating all quality features in a single formula. The use of prediction models accelerates the optimization of part design, applying multiple criteria to support decision-making. The methodology is applied to the design of a plastic support for induction hobs. Furthermore, this methodology has demonstrated that a weight reduction of 27% is feasible. However, it is necessary to combine process parameters that differ from the standard ones with a non-uniform thickness distribution so that the remaining injection parameters, material properties, and dimensions fall within tolerances.

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“…The coefficients of the reference temperature T S , the material-specific reference temperature T 0 , and the material temperature T can be summarized in Eq. 11 by the temperature shift factor T [47]. The constants C 1 and C 2 are dependent on the polymer and the reference temperature [48].…”

Section: Governing Equationsmentioning

confidence: 99%

“…Taking into account the fluid viscosity and the temperature influence in the form of the temperature shift factor, the equation is obtained as the Carreau-WLF model [47].…”

Section: Governing Equationsmentioning

confidence: 99%

Numerical simulation of the mold filling process and its experimental validation

Baum

Jasser

Stricker

et al. 2022

Int J Adv Manuf Technol

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The present study deals with the simulation of the filling process in injection molding using Ansys CFX and its experimental validation. For this purpose, the filling process of an exemplary mold is investigated numerically as well as experimentally at different time steps. For the numerical investigation, a suitable model is elaborated in Ansys CFX, which enables such a comparison. In particular, the representation of a suitable viscosity model for polymers is not common in Ansys CFX. Therefore, the Carreau-WLF viscosity model is adapted for the considered polymer Schulamind 66 SK 1000 and integrated into Ansys CFX. The contribution focuses on the comparison of the numerically calculated flow front contour and the respective filling levels of the melt from experiments. Furthermore, a detailed numerical analysis of temperature and viscosity profiles is included in order to illustrate the effect of shear-induced temperature changes and the interplay between the temperature field and the viscosity of the injected polymer. In conclusion, the numerical model nicely fits the experimental results despite some slight deviations in the early filling stages.

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CFD-Simulation der Kunststoffplastifizierung in einem Extruder mit durchgehend genutetem Zylinder und Barriereschnecke

Cited by 5 publications

References 12 publications

Approaches for Numerical Modeling and Simulation of the Filling Phase in Injection Molding: A Review

Approaches for Numerical Modeling and Simulation of the Filling Phase in Injection Molding: A Review

Predictive Methodology for Quality Assessment in Injection Molding Comparing Linear Regression and Neural Networks

Numerical simulation of the mold filling process and its experimental validation

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