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.     

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     

Local fracture resistance based on microstructural efficiency concept and simulation of injection molding

Local fracture resistance (FR) of short (SGF) and discontinuous long glass fibre (LGF) reinforced polypropylene (PP) was predicted using the ‘microstructural efficiency concept’ together with a simulation program for fibre orientation in injection molding. The ‘microstructural efficiency concept’ describes the relation between microstructural parameters such as the fibre content, the fibre aspect ratio and the processing (injection molding) induced layer structure taking also into account the local fibre orientation. The local fibre orientation in injection molding was predicted with the MOLDFLOW^®-software. The predicted local FR was compared with the measured one, which was determined by using compact tension samples and linear elastic fracture mechanics (LEFM). The comparison showed, that for SGF-PP good consistence between the predicted and measured FR existed, for LGF-PP the discrepancy was higher. Yet for both materials, the ‘microstructural efficiency concept’ together with the results obtained from the simulation of the fibre orientation can be used for FR prediction of an injection molded workpiece.     

Experimental study of atomization patterns produced by the oblique collision of two viscoelastic liquid jets

Experimental observations and analysis are presented for the formation and atomization of the fluid sheet created by obliquely colliding jets of viscoelastic fluids. Solutions of mono-disperse polystyrene (PS) in diethylphthalate and of poly-disperse polyethylene oxide (PEO) in glycerol/water mixtures were used to investigate the effects of fluid elasticity on the break-up patterns generated by the impact of two jets ejected from nozzles with an internal diameter of 0.85 mm. Various regimes of behaviour were identified which depend on the jet speed. The structures observed for these elastic fluids differ somewhat from those previously reported for Newtonian viscous fluids, and also show different behaviours depending on the degree of viscoelasticity. This study focuses on the periodic atomization, the so-called fishbone pattern, which occurs when the impinging jets form a liquid sheet which breaks up into a regular succession of ligaments and droplets. High-speed flash photography reveals that low concentrations of polymers significantly affect the evolution of the sheet and its fragmentation, the shapes of the ligaments, and the final drop sizes. The maximum fishbone angle is defined and shown to be a useful tool to describe the variation of the atomization pattern with polymer concentration. For the PS solutions the variation of maximum fishbone angle with reduced polymer concentration (c/c^*) follows a single master curve, but although the same is true for PEO with high molecular weights, the curves remain separate for low molecular weights. Observation of the fishbone patterns formed by the oblique impact of jets may provide a useful tool to observe and characterize inter-chain interaction in high speed extensional flow of polymer solutions.     

Non-isothermal transient flow and molecular orientation during injection mold filling

The properties of injection molded products are directly related to the microstructure which in turn strongly depends on the flow kinematics and thermal history of the polymer melt during the filling process. In this study the mold filling process has been analyzed by using an FEM-code (FIDAP) to solve the equation of continuity, momentum, and energy under transient and non-isothermal conditions. As constitutive relation for a purely viscous fluid, the Bird-Carreau and Arrhenius model was chosen. The phenomenon at the flow front, its flow kinematics, and its significant implication on the microstructure of the part have been investigated in detail. Computed particle tracking showed good agreement with experiments under real processing conditions. Furthermore, a rather simple but effective and useful method for predicting the orientation distribution in an injection molded part was proposed. It was found that the local deformation near the solid wall may be considered as the main source for a typical layer of high orientation on the surface of the part. Received: 1 December 1999 Accepted: 9 August 2000     

An anisotropic rotary diffusion model for fiber orientation in short- and long-fiber thermoplastics

The Folgar–Tucker model, which is widely-used to predict fiber orientation in injection-molded composites, accounts for fiber–fiber interactions using isotropic rotary diffusion. However, this model does not match all aspects of experimental fiber orientation data, especially for composites with long discontinuous fibers. This paper develops a fiber orientation model that incorporates anisotropic rotary diffusion. From kinetic theory we derive the evolution equation for the second-order orientation tensor, correcting some errors in earlier treatments. The diffusivity is assumed to depend on a second-order space tensor, which is taken to be a function of the orientation state and the rate of deformation. Model parameters are selected by matching the experimental steady-state orientation in simple shear flow, and by requiring stable steady states and physically realizable solutions. Also, concentrated fiber suspensions align more slowly with respect to strain than models based on Jeffery's equation, and we incorporate this behavior in an objective way. The final model is suitable for use in mold filling and other flow simulations, and it gives improved predictions of fiber orientation for injection molded long-fiber composites.     

Mechanical behavior of amorphous polymers in shear

Based on the non-equilibrium thermodynamic theory, a new thermo-viscoelastic constitutive model for an incompressible material is proposed. This model can be considered as a kind of generalization of the non-Gaussian network theory in rubber elasticity to include the viscous and the thermal effects. A set of second rank tensorial internal variables was introduced, and in order to adequately describe the evolution of these internal variables, a new expression of the Helmholtz free energy was suggested. The mechanical behavior of the thermo-viscoelastic material under simple shear deformation was studied, and the “ viscous dissipation induced“ anisotropy due to the change of orientation distribution of molecular chains was examined. Influences of strain rate and thermal softening produced by the viscous dissipation on the shear stress were also discussed. Finally, the model predictions were compared with the experimental results performed by G‘ Sell et al. , thus the validity of the proposed model is verified.     

非等温黏弹性复杂流动的改进SPH方法模拟

非等温黏弹性流体广泛存在于自然界和工业生产中,准确预测黏弹性流体的非等温流动机理和复杂流变特性有着重要的应用价值.文章提出一种改进的光滑粒子流体动力学(smoothed particle hydrodynamics,SPH)方法对非等温黏弹性复杂流动进行了数值模拟,其中流体的黏弹特性通过eXtended Pom-Pom本构模型来表征.为了提高模拟结果的精度,采用了一种核函数梯度的修正算法;为了灵活地施加边界条件,发展了边界粒子和虚拟粒子相联合的边界处理方法;为了消除流动过程中的拉伸不稳定性,施加了粒子迁移技术.运用改进SPH方法数值模拟了液滴撞击固壁和F型腔注塑成型问题,通过与Basilisk软件得到的结果进行比较验证了改进SPH方法求解非等温黏弹性流体的有效性.通过利用不同粒子初始间距进行计算,评价了改进SPH方法的数值收敛性.研究了非等温流动相较于等温流动的不同流动特征,深入分析了不同热流变参数对流动过程的影响.数值结果表明,文章提出的改进SPH方法可稳定、准确地描述非等温黏弹性复杂流动的传热机理、复杂流变特性和自由面变化特性.     

A 3D study on the effect of gate location on the cooling of polymer by injection molding

Injection molding is one of the most widely used plastic part processing. The quality of the injection molded part is a function of plastic material, part geometry, mold structure and process conditions. Gate location is among the most critical factors in achieving dimensionally accurate parts and high productivity of the molding process. To investigate the effect of the gate location on the cooling of polymer by injection molding, a full three dimensional time-dependent analysis is carried out for a mold with cuboids-shape cavity having two different thicknesses. The cooling of the polymer material is carried out by cooling water flowing inside six horizontal circular channels. Three gate locations are assumed, normal to the cavity surface, normal to the small thickness of the cavity, and normal to the large thickness of the cavity. A numerical model by finite volume is used for the solution of the physical model. A validation of the numerical model is presented. The results show that the gate location normal to the small thickness of the cavity achieves the minimum time required to completely solidify the product and minimum solidification of the product during the filling stage. They also indicate that the temperature distribution through the output product is greatly affected by the position of the injection gate location.     

黏弹性材料等效分数阶微观结构标准线性固体模型

从黏弹性材料微观链结构出发,以橡胶基黏弹性材料超弹性理论分子网链高斯(Gauss)统计模型和黏滞流动理论为基础,研究黏弹性材料的微观结构、填料等对黏弹性性能的影响.用温频等效原理描述温度对黏弹性材料力学性能的影响,建立了可以有效描述黏弹性材料耗能特性的等效分数阶微观结构标准线性固体模型.采用动态热机械分析仪(DMA)对高聚物黏弹性材料力学性能、耗能能力进行测试.试验表明:在低温区域,储能模量较大,随着温度的升高,储能模量下降显著;能量损耗因子在高温和低温区域数值较小,在玻璃化转变温度附近数值较高.根据测试数据对所提等效分数阶微观结构标准线性固体模型进行验证,该力学模型能够较好地描述黏弹性材料储能模量和能量损耗因子随温度的变化趋势.用9050A和ZN22黏弹性材料对模型的有效性进一步验证,结果表明:9050A和ZN22黏弹性材料具有较好的耗能能力,所提出的等效分数阶微观结构标准线性固体模型能够准确地描述微观结构和填料对黏弹性材料宏观性能的影响,能够准确地描述黏弹性材料在不同温度和频率下的动态力学性能.     

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.     

Separation strain rate dependence on the failure of polymer adhesion with mobile promoters

Comprehensive molecular dynamics simulations, employing a coarse-grained bead-spring model, are conducted to study the failure of adhesion between two immiscible polymers stitched together via mobile promoters. A realistic model under separating tension is constructed that enables both chain pulling out viscously and bulk dissipation in two dissimilar glassy polymers that one is dense melt and another is loose. The contributions to the adhesion energy from thermodynamics and chain suction are studied for dependence of the strain rate at fixed basic molecular parameters. With low density of connectors, either adhesion toughness or strength changes slightly with separation strain rate as viscous loss is negligible. But rate effects become evident for long connectors with high density, viscoelastic sliding friction and reptation of chains dominate and the fracture energy increases with strain rate. The results provide insights into the evolution of adhesion surfaces coupled with promoter molecular slipping out of bulk melts, which are useful for future developments of continuum models for failure of polymeric interfaces.     

Injection and Storage of CO<Subscript>2</Subscript> in Deep Saline Aquifers: Analytical Solution for CO<Subscript>2</Subscript> Plume Evolution During Injection

Injection of fluids into deep saline aquifers is practiced in several industrial activities, and is being considered as part of a possible mitigation strategy to reduce anthropogenic emissions of carbon dioxide into the atmosphere. Injection of CO₂ into deep saline aquifers involves CO₂ as a supercritical fluid that is less dense and less viscous than the resident formation water. These fluid properties lead to gravity override and possible viscous fingering. With relatively mild assumptions regarding fluid properties and displacement patterns, an analytical solution may be derived to describe the space–time evolution of the CO₂ plume. The solution uses arguments of energy minimization, and reduces to a simple radial form of the Buckley–Leverett solution for conditions of viscous domination. In order to test the applicability of the analytical solution to the CO₂ injection problem, we consider a wide range of subsurface conditions, characteristic of sedimentary basins around the world, that are expected to apply to possible CO₂ injection scenarios. For comparison, we run numerical simulations with an industry standard simulator, and show that the new analytical solution matches a full numerical solution for the entire range of CO₂ injection scenarios considered. The analytical solution provides a tool to estimate practical quantities associated with CO₂ injection, including maximum spatial extent of a plume and the shape of the overriding less-dense CO₂ front.     

A study of emulsion expansion by a boundary integral method

A new implementation of the conventional three-dimensional boundary-integral formulation for deformable drops in a viscous medium at low Reynolds numbers is presented. We describe a scheme to generate concentrated emulsions and a numerical procedure for computing interactions among deformable drops. Direct numerical simulations are used to describe the expansion of an ordered emulsion at dispersed-phase volume fraction up to 0.98. We also study the viscoelastic response of a monodisperse emulsion which have been concentrated up to 0.68. The results have demonstrated the feasibility of simulating high-volume fraction emulsions, and the method can readily be extended to explore three-dimensional foam problems.     

微振激励下黏弹性阻尼器微观链结构力学模型

减小微振动对高精密仪器至关重要,利用黏弹性阻尼器进行微振动抑制是一个新兴而又具有挑战性的课题.本文采用分子链网络模型方法分析了黏弹性材料的微观分子链结构,综合考虑材料分子链结构中的网络链和自由链对黏弹性材料力学性能的影响,提出一种基于材料微观分子链结构的微振激励下黏弹性阻尼器力学模型.模型分别采用标准线性固体模型和Maxwell模型来描述网络链和自由链中单个链的力学性能,并分别采用8链网络模型和3链网络模型考虑两种类型分子链的综合效应,引入温频等效原理描述温度对微振激励下黏弹性阻尼器力学性能的影响.该模型能够描述温度和频率对黏弹性阻尼器动态力学性能的影响,并能够反映黏弹性材料的微观结构与材料力学性能的关系.为验证所提模型的有效性及考察黏弹性阻尼器在微振激励下的耗能能力和动态力学性能,在微振条件下对黏弹性阻尼器进行了动态力学性能试验.研究结果表明黏弹性阻尼器具有较好的微振耗能能力,其动态力学性能受温度和频率影响较大,所提的力学模型能够精确地描述微振激励下黏弹性阻尼器动态力学性能随温度和频率的变化关系.      

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.     

Surface waves in nematic liquid crystals

The problem of small-amplitude harmonic wave propagation along the surface of an incompressible nematic liquid crystal is considered when the evolution of the orientation vector is specified by viscous stresses and the orientational elasticity can be ignored. An analytic solution and a dispersion relation are obtained in the case of the planar and homeotropic initial orientation of this vector.     

Two‐dimensional non‐Newtonian injection molding with a new control volume FEM/volume of fluid method

A new method based on volume of fluid for interface tracking in the simulation of injection molding is presented. The proposed method is comprised of two main stages: accumulation and distribution of the volume fraction. In the first stage the equation for the volume fraction with a noninterfacial flux condition is solved. In the second stage the accumulated volume of fluid that arises as a consequence of the application of the first one is dispersed. This procedure guarantees that the fluid fills the available space without dispersion of the interface. The mathematical model is based on two‐phase transport equations that are numerically integrated through the control volume finite element method. The numerical results for the interface position are successfully verified with analytical results and numerical data available in the literature for one‐dimensional and two‐dimensional domains. The transient position of the advance fronts showed an effective and consistent simulation of an injection molding process. The nondispersive volume of fluid method here proposed is implemented for the simulation of nonisothermal injection molding in two‐dimensional cavities. The obtained results are represented as transient interface positions, isotherms and pressure distributions during the injection molding of low density polyethylene. Copyright © 2012 John Wiley & Sons, Ltd.