注塑模充模过程动态分析

注塑成型是利用型腔模制造理想制品主要的成型加工方式 ,塑料熔体的流动行为将直接影响着最终塑件的质量 ,塑料熔体在三维薄壁型腔内的流动属于带有运动边界的粘性不可压缩流体的流动 ,本文针对塑料注塑成型特点 ,经过量纲分析和引入合理而必要的假设 ,得到了适合于充模分析的数学模型。控制方程的求解主要包括三个阶段 :压力场、温度场和流动前沿位置的确定。数值求解采用有限元法求解压力场、有限差分法求解温度场、并利用控制体积法跟踪熔体前沿 ,实现了充模过程的动态模拟     

聚合物注射成型流动残余应力的数值分析

建立了可压缩黏弹性聚合物熔体在薄壁型腔中充模/保压过程中非等温、非稳态流动 的数学模型,用数值方法实现了注射成型过程中流动应力和取向建立及松弛过程的模拟,研 究了熔体温度、模具温度和注射速率等工艺条件对分子冻结取向的影响,取得了与实验相符 的结果.     

三维非牛顿熔体前沿界面的Level Set/Ghost/SIMPLEC模拟

建立了三维粘性不可压非牛顿流体流动的控制方程,采用Level Set/Ghost/SIMPLEC方法模拟了注塑成型充模阶段的三维流动过程;追踪到了不同时刻的熔体前沿界面,预测并分析了流动过程中不同时刻的压力、速度等重要的流动特征参数,并与牛顿流体相应的流动特征参数做了对比.研究结果表明:Lovol Set/Ghost/SIMPLEC方法可以准确追踪非牛顿熔体前沿界面:幂律熔体在流动过程中的压差明显大于牛顿熔体的压差,沿横截面的速度分布也有明显的差别.     

基于实体的注射成型流动模拟

提出了应用中面模型技术模拟实体模型的注射成型流动过程的新方法。对实体模型的表面进行二维网格划分，将结点在厚度方向上配对．配对点之间添加虚拟热流道单元，建立二维有限元分析的网格模型。将HeleShaw流动应用于非等温条件下的粘性、不可压缩流体，建立基于中面模型流动分析的数学模型，用充填园子的输运方程描述流动前沿。用有限元计算充填过程的压力场．有限差分计算温度场，高阶的Taylor展开式计算每一时间步长的充填因子。针对Han设计的试验模具，用相同的材料及工艺条件，比较中面模型和实体模型的模拟结果。算例分析表明，这种方法可以有效地模拟基于实体模型的注射成型流动过程。     

塑料注射成型保压过程的数值模拟

保压过程是塑料注射成开型一个重要阶段，它直接关系到最终制件的内部结构、尺寸稳定性和变形等，本文在对塑料注射成型保压过程进行深入分析的基础上，基于合理的假设和选用恰当的材料模型，导出了保压过程可压缩、非牛顿粘性流体在模具型腔中非等温流动的控制方程，采用有限元/有限差分混合法实现了对保压过程的模拟，并通过算例讨论了保压压力、浇口凝固时间、锁模力等工程关心的实际问题。     

水辅成型中的穿透机理研究

针对一次穿透理论在预测残余壁厚方面的局限,提出了厚度方向再穿透理论及算法。建立了量纲为一的黏性可压缩非牛顿熔体在水辅成型厚度方向再穿透中的控制方程,导出了求解压力场的变分方程和速度场的计算公式,用分部积分和力学基本原理建立了再穿透速度与注水压力、熔体密度、黏度、穿透长度、穿透半径之间的关系,并开发了模拟程序。实验结果表明应用厚度方向再穿透理论可以有效地提高水辅成型的预测精度。     

黏性不可压缩流体流动前沿的数值模拟

提出了模拟注射成型中黏性、不可压缩流体流动前沿的新方法. 将Hele-Shaw流动应用于非 等温条件下的黏性、不可压缩流体，建立了流动分析模型，用充填因子的输运方程描述流动 前沿. 应用高阶Taylor展开式计算每一时间步长的充填因子，用Galerkin方法导出了计算 充填因子各阶导数的递推公式. 给出了时间增量的选取方法，证明了它的稳定性. 针对Han 设计的试验模具，用相同的材料及工艺条件模拟充填过程，比较了传统方法和该方法的模 拟结果与实验结果的差异. 算例分析表明，该方法可以有效地提高注射成型中流动前沿的 模拟精度和计算效率.     

注塑成型流动诱导应力的数值计算

根据注塑成型的特点引入合理的假设,简化了粘性、可压缩、非等温塑料熔体流动的控制方程及基于PTT(Phan Thien Tanner)模型的本构方程,用分部积分法推导了关于压力场的拟Poisson方程,用待定系数法导出了流动应力的解析表达式.用有限元法求解压力场,有限差分及"上风"法离散求解温度场,根据解析表达式计算速度场及应力场,再进行应力-速度迭代求出非线性问题的最终解.比较了PC材料的模拟结果与光弹实验结果,模拟结果与实验结果基本一致.     

用迭代法模拟注塑成型的三维流动

Hele-Shaw模型是模拟注塑成型过程的常用模型,它的主要缺点是不能模拟一些重要的物理现象及引入实际制件中并不存在的“中面”概念,为了消除这些不足,本文开发了真三维的流动分析程序。建立了粘性、不可压缩的非牛顿流体流动的控制方程,为了避免同时求解耦合的压力场、速度场,本文引入拟稳定技术独立地求解这些方程,用迭代法求耦合方程的解。这种方法可以减少内存并提高数值方法的稳定性。算例表明数值结果与实验结果吻合较好,这种方法成功地模拟了注塑成型流动过程中的重要特征。     

气体辅助注射成型过程动力学分析

基于气体穿透机理和Hele-Shaw流动模型,对管状模腔中气体冲破熔体前沿形成中空制品气辅成型过程进行了研究,推导出反映充模流动压力梯度比、非牛顿幂率指数等影响因素与计算表层熔体厚度比之间关系的数学公式,建立了熔体前沿和气体前沿速度与位移演化关系的数学模型,分别得出了牛顿流体和非牛顿流体选取不同影响参数时熔体前沿和气体前沿速度、位移的演化曲线.模拟结果表明,所建数学模型能较好的反映熔体前沿和气体前沿速度、位移演化关系.在气体冲破熔体前沿以前,气体接近匀加速运动,前沿位移梯度逐渐增加;熔体前沿的速度几乎保持不变,位移随时间接近线性增长.当气体冲破熔体前沿时,熔体和气体前沿的速度和位移均急速上升.     

Computing flow-induced stresses of injection molding based on the Phan–Thien–Tanner model

A numerical approach is introduced to solve the viscoelastic flow problem of filling and post-filling in injection molding. The governing equations are in terms of compressible, non-isothermal fluid, and the constitutive equation is based on the Phan–Thien–Tanner model. By introducing some hypotheses according to the characteristics of injection molding, a quasi-Poisson type equation about pressure is derived with part integration. Besides, an analytical form of flow-induced stress is also generalized by using the undermined coefficient method. The conventional Galerkin approach is employed to solve the derived pressure equation, and the ‘upwind’ difference scheme is used to discrete the energy equation. Coupling is achieved between velocity and stress by super relax iteration method. The flow in the test mold is investigated by comparing the numerical results and photoelastic photos for polystyrene, showing flow-induced stresses are closely related to melt temperatures. The filling of a two-cavity box is also studied to investigate the viscoelastic effects on real injection molding.     

Numerical simulation method for viscoelastic flows with free surfaces—fringe element generation method

To simulate filling flow in injection moulding for viscoelastic fluids, a numerical method, based on a finite element method and a finite volume method, has been developed for incompressible isothermal viscoelastic flow with moving free surfaces. The advantages of this method are, first, good applicability to arbitrarily shaped mould geometries and, second, accurate treatment for boundary conditions on the free surface. Typical filling flows are simulated, namely filling flow into a 1:4 expansion cavity with and without an obstacle. Numerical results predict the position of weld lines and air-traps. The method also indicates the effects of elongational flow on molecular orientation.     

半解析有限元法分析非线性粘弹体在板材模具中的流动

聚合物熔体在模具中的均匀性决定板材成型的质量。熔体具有非线性记忆性的粘弹效应,同时流道十分复杂。为准确、简便地分析熔体流动情况,针对板材机头流道的特点,提出了流动计算新的方法——有限柱半解析法,即在流道的厚度方向采用富氏级数描述流动分布,把三维有限元方程简化成为二维,得到以流量和压力为未知量的有限元方程。同时采用K-BKZ积分型本构模型描述熔体的非线性记忆性,给出求解非线性方程组的迭代方法,取得较好的收敛性。对两种典型的板材模具进行了分析计算,得出模具出口处的流量分布,通过把结果与三维有限元分析的结果相比较,表明该方法可以准确地分析板材模具中熔体的流动。     

成型充填过程的ALE有限元模拟

在ALE框架中提出了一个用于成型充填过程有限元数值模拟的模型。应用ALE参考构形及ALE参考粒子速度描写充填过程中的熔体质量运动。摒弃了Hele-Shaw近似假定,因而所提出的模型能用于非薄壁型腔中高分子材料充填过程的数值模拟。应用基于时域分步算法的Taylor-Galerkin方法,对控制成型充填过程的守恒方程建立了弱形式。对移动自由面附近的充填材料区构造了网格生成算法与网格重划分方案。给出了在几种不同形状的典型腔体中充填过程的数值模拟结果,表明了所提出的ALE有限元模型模拟充填过程的有效性。     

A mixed finite element scheme for viscoelastic flows with XPP model

A mixed finite element formulation for viscoelastic flows is derived in this paper, in which the FIC （finite incremental calculus） pressure stabilization process and the DEVSS （discrete elastic viscous stress splitting） method using the Crank-Nicolson-based split are introduced within a general framework of the iterative version of the fractional step algorithm. The SU （streamline-upwind） method is particularly chosen to tackle the convective terms in constitutive equations of viscoelastic flows. Thanks to the proposed scheme the finite elements with equal low-order interpolation approximations for stress-velocity-pressure variables can be successfully used even for viscoelastic flows with high Weissenberg numbers. The XPP （extended Pom-Pom） constitutive model for describing viscoelastic behaviors is particularly integrated into the proposed scheme. The numerical results for the 4：1 sudden contraction flow problem demonstrate prominent stability, accuracy and convergence rate of the proposed scheme in both pressure and stress distributions over the flow domain within a wide range of the Weissenberg number, particularly the capability in reproducing the results, which can be used to explain the ＂die swell＂ phenomenon observed in the polymer injection molding process.     

RTM充模过程数值模拟的隐式有限元算法

建立了基于欧拉方法描述树脂传递模塑(RTM)工艺充模过程的基本数学方程,并采用有限元隐式时间积分方法对基本方程进行了数值求解．编制了基于隐式有限元算法及传统有限元控制体算法的程序,通过具体算例比较了这两种算法的优缺点．与传统的有限元控制体法相比,该文提出的隐式有限元算法能节省计算时间,特别适合于单元、节点数目多的情况．隐式有限元算法是一种纯有限元方法,不需要使用控制体积技术,采用该算法计算出的流动前沿与时间步长无关。     

Numerical simulation of high‐Reynolds number flow around circular cylinders by a three‐step FEM–BEM model

An innovative computational model, developed to simulate high‐Reynolds number flow past circular cylinders in two‐dimensional incompressible viscous flows in external flow fields is described in this paper. The model, based on transient Navier–Stokes equations, can solve the infinite boundary value problems by extracting the boundary effects on a specified finite computational domain, using the projection method. The pressure is assumed to be zero at infinite boundary and the external flow field is simulated using a direct boundary element method (BEM) by solving a pressure Poisson equation. A three‐step finite element method (FEM) is used to solve the momentum equations of the flow. The present model is applied to simulate high‐Reynolds number flow past a single circular cylinder and flow past two cylinders in which one acts as a control cylinder. The simulation results are compared with experimental data and other numerical models and are found to be feasible and satisfactory. Copyright © 2001 John Wiley & Sons, Ltd.     

Two-dimensional viscoelastic flows: experimentation and modeling

Extensive experimental data on the birefringence in converging and diverging flows of a polymeric melt have been obtained. The birefringence and pressure drop measurements were carried out in working cells of planar geometry having different contraction angles and contraction ratios. For investigation of diverging or abrupt expansion flow, the direction of flow in the cells was reversed. The theoretical predictions are based upon the Leonov constitutive equation and a finite element scheme with streamwise integration.In contrast to Newtonian and second-order fluids, viscoelastic fluids at high shear rates show significant differences in pressure drop and birefringence (i.e. stresses) in converging and diverging flows. For a constant flow rate, the pressure drop is higher and the birefringence smaller in diverging flows than in converging flows. This difference increases with increasing flow rate. Further, for the same contraction ratio but different contraction angles, the birefringence maximum increases considerably with contraction angle. In addition, an increase in contraction ratio has the same effect.The viscoelastic constitutive equation of Leonov has been shown to describe all the above viscoelastic effects observed in the experiments. In general, a reasonable agreement between theory and experiment has been obtained, which shows the usefulness of the Leonov model in describing actual flows.