To read the full version of this content please select one of the options below:

A robust finite volume method for three-dimensional filling simulation of plastic injection molding

Junjie Liang (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)
Wan Luo (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)
Zhigao Huang (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)
Huamin Zhou (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)
Yun Zhang (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)
Yi Zhang (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)
Yang Fu (State Key Laboratory of Materials Processing and Die & Mold Technology, Huazhong University of Science and Technology , Wuhan, China)

Engineering Computations

ISSN: 0264-4401

Article publication date: 2 May 2017

Downloads
232

Abstract

Purpose

The purpose of this paper is to develop a finite volume approach for the simulation of three-dimensional two-phase (polymer melt and air) flow in plastic injection molding which is capable of robustly handling the mesh non-orthogonality and the discontinuities in fluid properties.

Design/methodology/approach

The presented numerical method is based on a cell-centered unstructured finite volume discretization with a volume-of-fluid technique for interface capturing. The over-relaxed approach is adopted to handle the non-orthogonality involved in the discretization of the face normal derivatives to enhance the robustness of the solutions on non-orthogonal meshes. A novel interpolation method for the face pressure is derived to address the numerical stability issues resulting from the density and viscosity discontinuities at the melt–air interface. Various test cases are conducted to evaluate the proposed method.

Findings

The presented method was shown to be satisfactorily accurate by comparing simulations with analytical and experimental results. Besides, the effectiveness of the proposed face pressure interpolation method was verified by numerical examples of a two-phase flow problem with various density and viscosity ratios. The proposed method was also successfully applied to the simulation of a practical filling case.

Originality/value

The proposed finite volume approach is more tolerant of non-orthogonal meshes and the discontinuities in fluid properties for two-phase flow simulation; therefore, it is valuable for engineers in engineering computations.

Keywords

Acknowledgements

The authors would like to acknowledge financial support from the National Natural Science Foundation Council of China (Grant No. 51210004, 51575207) and the National Program on Key Basic Research Project (Grant No. 2012CB025903).

Citation

Liang, J., Luo, W., Huang, Z., Zhou, H., Zhang, Y., Zhang, Y. and Fu, Y. (2017), "A robust finite volume method for three-dimensional filling simulation of plastic injection molding", Engineering Computations, Vol. 34 No. 3, pp. 814-831. https://doi.org/10.1108/EC-03-2016-0102

Publisher

:

Emerald Publishing Limited Bingley, United Kingdom

Copyright © 2017, Emerald Publishing Limited