Full Three-Dimensional Mold Filling Simulation

2 Full Three-Dimensional Mold Filling Simulation 

Based on the control volume approach and using the three-dimensional finite element formulations for heat conduction with convection and momentum balance for non-Newtonian fluids presented earlier, Turng and Kim [10] and [17] developed a three-dimensional mold filling simulation using 4-noded tetrahedral elements. The nodal control volumes are defined by surfaces that connect element centroids and sides as schematically depicted in Fig. 9.33. 

The element side surfaces are formed by lines that connect the centroid of the triangular side and the midpoint of the edge. Kim s definition of the control volume fill factors are the same as described in the previous section. Once the velocity field within a partially filled mold has been solved for, the melt front is advanced by updating the nodal fill factors. To test their simulation, Turng and Kim compared it to mold filling experiments done with the optical lenses shown in Fig. 9.34. The outside diameter of each lens was 96.19 mm and the height of the lens at the center was 19.87 mm. The thickest part of the lens was 10.50 mm at the outer rim of the lens. The thickness of the lens at the center was 6 mm. The lens was molded of a PMMA and the weight of each lens was 69.8 g. 

The polymer melt viscosity was simulated using a cross-model given by 

Turng and Kim used the material properties listed in Table 9.4. 

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