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.     

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     

铸造充型流动过程的三维数值模拟

本文以ＳＯＬＡ－ＶＯＦ方法为基础，结合作者提出的三维自由表面边界速度确定方法，实现了铸造充型流动过程的三维数值模拟，模拟结果准确地提供了液体金属在充型过程中的流动形态、充型时间、流量等实用的参数．这表明，通过数值计算的手段，对用实验方法难以观测的铸造充型流动过程进行分析研究是有意义可行的，所得到的参数有助于铸造工艺的设计及优化     

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。     

注塑成型充填／后充填过程统一的可压缩流动分析

注塑成型是重要的塑料成型工艺,成型过程中熔体在模腔中的流动和传热对最终制品的性能和质量有重要的影响,因此,精确预测注塑过程的流动及传热历史,并进一步预测注塑制品的收缩、翘曲和机械性能等性能和质量指标具有重要意义。为了精确地描述成型过程中材料的流动及传热行为,本文针对注塑成型过程的工艺特点,将充填后充填过程作为一个统一的过程,考虑材料可压缩性及相变对充填和后充填过程的影响,建立了充填后充填过程的统一数学模型。采用有限元/有限差分/控制体积混合数值方法,实现了注塑成型充填后充填一体化模拟。数值模拟结果与实验结果的对比,验证了本文模型和算法。     

微纳米结构壁面对流场及动压润滑的影响研究

固体边界具有的微纳米结构将影响流体在近壁面处的流动行为,进而由于尺度效应改变流体在整个微间隙的流动或润滑规律.将壁面可渗透微纳米结构等效为多孔介质薄膜,采用Brinkman方程来描述流体在近壁面边界渗透层内的流动,并将其与自由流动区域的不可压缩流体Navier-Stokes控制方程耦合,在界面处的连续边界条件下求解和分析了速度分布规律和压力变化规律.针对恒定法向承载力的油膜润滑条件,进一步讨论了静止表面或运动表面的微纳米结构对近壁面流动行为的影响;并揭示了考虑壁面微纳米结构的流体动压润滑的油膜厚度和摩擦系数的变化规律.论文结果为具有可渗透微结构表面的微间隙流动与润滑提供了理论参考.     

考虑稠密气体效应的微尺度气体轴承模拟

当气体流动区的局部压力升高到一定程度时,气体稠密效应对其输运特性的影响不可忽略,其影响可以用Enskog理论来描述。利用直接模拟蒙特卡罗(DSMC)方法以及考虑气体分子稠密效应的衍生方法对气体粘度随特征尺度的变化规律和气体粘度随密度变化的规律进行了计算分析,在此基础上研究了考虑稠密效应的微尺度气体轴承的承载能力。计算结果表明,稠密效应在抵消掉气体稀薄效应的同时还改变了输运系数和气体薄膜的润滑特性,提高了气体轴承的承载能力。     

微/纳器件粗糙表面间弯月面力及黏着力计算

微/纳器件表面微观粗糙结构间由于液体介质而引起的弯月面力和黏着力是导致器件精度降低乃至失效的主要原因之一。通过建立微/纳米尺度上球面-平面接触的物理模型,基于Young-Laplace方程和Reynolds润滑理论,分析得到粗糙表面接触分离过程中弯月面力和黏着力的计算公式。在此基础上,计算得到接触表面分离过程中的弯月面形状变化规律,并分别讨论了固体表面分离距离、液滴初始弯月面高度、固体表面润湿性能和分离时间等因素对弯月面力和黏着力的影响。研究结果为微/纳米表面抗黏着机理提供了理论依据。     

考虑微结构连接性的双尺度结构自然频率拓扑优化

多孔材料因具有轻量化、高孔隙率和减振/散热等优良多物理特性,在航空航天等领域具有广阔应用前景。采用拓扑优化方法对含多种多孔材料的结构进行结构与材料微结构构型一体化设计,有助于获得具有优良力学性能的结构设计。然而,传统逆均匀化微结构设计方法无法确保不同多孔材料微结构之间的连接性,设计结果不具备可制造性。本文面向含多种多孔材料的双尺度结构基频最大化设计问题,考虑不同微结构之间的连接性,协同设计多孔材料的微结构构型及其在宏观尺度下的布局。采用均匀化方法计算多孔材料的宏观等效力学性能,通过对不同多孔材料微结构单胞的边界区域采用相同的拓扑描述确保双尺度优化过程中任意空间排布下不同微结构的连接性,并通过优化算法确定微结构间的连接形式及微结构拓扑。在宏观尺度,提出结合离散材料插值模型和RAMP插值模型RAMP (Rational Approximation of Material Properties)的多孔材料各向异性宏观等效刚度及质量插值模型,获得清晰的多孔材料宏观尺度布局并减轻优化过程中伪振动模态的影响。建立以双尺度结构基频最大化为目标,以材料用量为约束的优化列式,推导灵敏度表达式,并基于梯度优化算法求解双尺度结构拓扑优化问题。数值算例表明,采用本文优化方法能够有效确保基频最大化双尺度结构设计中不同多孔材料微结构之间的连接性,增强优化设计结果的可制造性。     

钢球检测用展开轮表面微结构增摩降磨特性分析

针对钢球缺陷检测过程中,镜面钢球打滑引起的滑动摩擦导致展开轮磨损这一问题,以实现展开轮增摩降磨为目标,提出将微结构应用于钢球展开轮表面的方法.首先,应用激光微造型技术在T10A试件表面加工不同特征参数凹坑微结构,采用单因素法在MMW-1立式万能磨擦试验机上进行点接触干滑动摩擦试验;在综合考虑局部激光硬化和几何参数对磨损性能影响的基础上,结合试验数据建立基于Archard理论的微结构磨损模型;最后通过仿真技术及磨损试验验证磨损模型的正确性,进而对微结构特征参数进行优选.结果表明:在点接触干滑动摩擦工况下,提出的三种微结构表面均可以实现增摩降磨;建立的磨损模型能准确地计算磨损系数用以分析实际工况的磨损特性;优选了凹坑面积在S_2~S_4范围内的菱形微结构.提出的方法为钢球表面缺陷检测设备提供了技术支持,所建的磨损模型为干摩擦状态下凹坑微结构表面磨损程度的预测提供了理论参考.     

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。     

Experimental and numerical investigation of a viscoplastic Carbopol gel injected into a prototype 3D mold cavity

A numerical model for free-surface flow of a viscoplastic liquid into a cavity is presented. This flow is regarded as a basic model of injection molding, which is a widely used processing technology. Model experiments of the injection process are performed with a water-based gel with shear-thinning behavior. The filling process is visualized by tracing the free surface of the gel within the cavity. Filling times of the cavity are deduced from the experimental observations. The filling process is also analyzed by means of numerical simulation.The flow equations are integrated according to the finite-volume method. The volume-of-fluid method is employed in order to describe the flow of two incompressible, immiscible phases, the phase interface is resolved by the method of geometric reconstruction or alternatively by the method of surface compression. The Herschel–Bulkley model is used in order to describe the shear-thinning behavior of the gel and the effects of a yielding point. The governing equations of the flow are solved by means of the commercial code Fluent as well as the Open Source code OpenFOAM.The results of the numerical simulations are analyzed in detail. They are compared with the experimental findings. Cavity filling times in the experiments and the simulations are in good agreement. Different patterns of the filling flow depending on the injection parameters are evident in the experiments and the simulations. They are characterized and arranged with respect to the similarity parameters of the flow configuration. Again, the results of the simulation are found to agree well with the experimental observations.     

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.     

Convected level set method for the numerical simulation of fluid buckling

‘Fluid buckling’ is a phenomenon characterized mainly by the existence of fluid toroidal oscillations during flow. It appears when a high viscosity fluid flows vertically against a flat surface and may occur in industrial applications, as in injection molding of a propergol in complex‐shaped cavities. These coiling or folding oscillations appear during the mold filling stage, leading to air entrapment. To understand and to model this free surface flow problem, a convected level set method is proposed. First, a sinus filter is applied to the distance function to get a smooth truncation far from the interface. Second, the reinitialization is embedded in the transport equation model, avoiding it as a separate step during calculation. In order to validate the method, numerical results are presented on classical interface capturing benchmarks. Finally, results are shown on two‐dimensional and three‐dimensional viscous jet buckling problems. Copyright © 2010 John Wiley & Sons, Ltd.     

Penalty formulation for postfilling analysis during injection molding

We propose an approximate method that can simulate the packing stage during the injection molding using the penalty parameter method. In order to account for the compressibility effect, an update scheme based on similarity between the slightly compressible and the penalty formulations is proposed. The method allows for solving the entire injection molding process using a single algorithm with the penalty method in spite of the transition from the incompressible regime during the filling stage into the compressible regime for the packing stage. Several test cases have been presented to prove the validity of the method. It has been shown that the accuracy of the proposed method is identical to that of the mixed method. Copyright © 2007 John Wiley & Sons, Ltd.     

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.     

Modeling and simulation of the viscoelastic fluid mold filling process by level set method

A model for unifying a viscoelastic fluid and a Newtonian fluid is established, in which the governing equations for the viscoelastic fluid and the Newtonian fluid are successfully united into a system of generalized Navier–Stokes equations. A level set method is set up to solve the model for capturing the moving interface in the mold filling process. The physical governing equations are solved by the finite volume method on a non-staggered grid and the interpolation technique on the collocated grid is used for the pressure-velocity and the stress-velocity decoupling problems. The level set and its reinitialization equation are solved by the finite difference method, in which the spatial derivatives are discretized by the 5th-order Weighted Essentially Non-Oscillatory (WENO) scheme, and the temporal derivatives are discretized by the 3rd-order Total Variation Diminishing Runge–Kutta (TVD-R–K) scheme. The validity of the method is verified by some benchmark problems. Then a simulation of viscoelastic fluid mold filling process is pursued with the method. The moving interface and all the information of the physical quantities during the injection process are captured. The die swelling phenomenon is found in the simulation. The influences of elasticity and viscosity on the physical quantities such as stresses etc. in the mold filling process are analyzed. Numerical results show that elastic characteristics such as the stretch and die swelling etc. reinforce accordingly as Weissenberg number increases. Pressures increase continuously in the mold filling process and the pressure maintains the maximum value at the inlet. Injection velocity is proportional to injection pressure. A higher viscosity leads to a higher pressure distribution, that is, the pressure decreases as Reynolds number increases.     

注塑模具浇口位置的演化设计方法

首先简要介绍了国内外浇口位置优化设计的研究现状,然后详细阐述了一种基于信息熵的离散变量演化算法的原理和程序实现步骤,将该算法与注塑模流动数值模拟程序相结合进行浇口位置优化设计,并将优化结果与Moldflow推荐的浇口位置进行了分析比较.算例表明,所提出的方法适用于注塑模具浇口位置优化,并且有较好的计算效率和精度.