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Research Papers

Surface Model Based Modeling and Simulation of Filling Process in Gas-Assisted Injection Molding

[+] Author and Article Information
Jianhui Li, Lei Chen, Dequn Li

State Key Laboratory of Mold and Die Technology, Huazhong University of Science and Technology, 1037 Luoyu Road, Wuhan, Hubei 430074, China

Huamin Zhou1

State Key Laboratory of Mold and Die Technology, Huazhong University of Science and Technology, 1037 Luoyu Road, Wuhan, Hubei 430074, Chinahmzhou@hust.edu.cn

1

Corresponding author.

J. Manuf. Sci. Eng 131(1), 011008 (Jan 13, 2009) (8 pages) doi:10.1115/1.3063653 History: Received December 17, 2007; Revised December 07, 2008; Published January 13, 2009

Present gas-assisted injection molding simulations are all based on either a midplane model or a 3D model, in which second modeling is unavoidable for a midplane model, and a 3D simulation needs a full-scale three-dimensional discretization of parts leading to unsustainable computing time and unstable numerical analysis. In this paper, surface model based modeling and numerical simulation of gas-assisted injection molding are proposed. By taking the influence of gas penetration on melt flow as boundary conditions of the melt-filling region, a hybrid control-volume finite element/finite-difference method (CV/FEM/FDM) similar to conventional injection molding simulation is employed. The gas penetration interface within the gas channel is solved by applying the matching asymptotic expansion method, which educes an analytical model of the gas penetration thickness ratio. A technology of generating gas-channel mesh semiautomatically is put forward, which combines selecting the path of gas channel manually and calculating the parameters of gas nodes automatically. The second modeling is thus avoided. The proposed model and simulation are verified by comparing with the experiment.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

Schematic notation for flow regions and their interface in gas-assisted injection molding: (1) the solid frozen layer, (2) the penetration gas, (3) the deforming viscous melt, (4) the unfilled cavity, (I) the gas front, and (II) the melt front

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Figure 2

Schematic notation for gas penetration in circular gas channel: (a) radial penetration and (b) axial penetration

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Figure 3

Illustration for (a) the outer coordinate system and (b) the inner coordinate system

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Figure 4

Involved concepts for gas-channel mesh: (1) gas channel, (2) surface boundary, (3) path of gas channel, and (4) center line of gas channel

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Figure 5

Schematic notation for gas-channel mesh

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Figure 6

Flow chart for numerical implement of GAIM

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Figure 10

The simulation by HSCAE : (a) the surface model composed of triangle element and (b) the penetration thickness

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Figure 11

The simulation by MOLDFLOW : (a) the tetrahedral finite element and (b) the penetration thickness

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Figure 12

The comparison between experimental result and the corresponding results of simulation by MOLDFLOW and HSCAE

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Figure 9

The geometry of the experimental test part

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Figure 7

Schematic notation for control volume of gas node

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Figure 8

Schematic notation for filling status in gas-channel mesh

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Figure 13

The simulated penetration thickness under new processing settings by (a) HSCAE and (b) MOLDFLOW

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