Melt flow, simulation, finite element

D. Givoli, J. E. Flaherty, M. S. Shephard. Simulation of Czochralski melt flows using parallel adaptive finite element procedures. Model Simul Mater Sci Eng 4 623, 1996. 

Klein, 1., The Melting Factor in Extruder Performance, SPEL, 28, 47 (1972) Altinkaynak, A., Three-Dimensional Finite Element Simulation of Polymer Melting and Flow in a Single-Screw Extruder Optimization of Screw Channel Geometry, Ph. D. Thesis, Michigan Technological University, Houghton, MI (2010)... 

This paper describes a finite element formulation designed to simulate polymer melt flows in which both conductive and convective heat transfer may be important, and illustrates the numerical model by means of computer experiments using Newtonian extruder drag flow and entry flow as trial problems. Fluid incompressibility is enforced by a penalty treatment of the element pressures, and the thermal convective transport is modeled by conventional Galerkin and optimal upwind treatments. 

In the FEM calculation, software is used that operates on the finite element method. A data model of the mold or a mold part is read into the software. The data model also includes the part contour. Under certain conditions (cavity temperature, melt temperature, etc.), a temperature control layout is designed around the molded part with the help of special software. The computer can then simulate three-dimensional temperature distribution in the mold. If undesirable temperature values occur in certain areas, the previously defined temperature channel layout can be changed. Through the simulation, the temperature control system can be virtually changed until a possibly optimum condition is achieved. The advantage of this technique is that the simulation allows a three-dimensional view of the heat flows and temperatures. In addition, this technique is very accurate (but only if the boundary conditions have been practically defined ). The disadvantages are the costs and the need for specialized staff and appropriate software licenses. Therefore, such designs are often purchased as a service. 

In the study, the mathematical model of the polymer melt flows in the extrusion process of plastic profile with metal insert was developed and the complex melt rheological behavior was simulated based on the finite element method. The melt flow characteristic in the flow channel was analyzed. The variation of the melt pressure, velocity, viscosity and stress versus different metal insert moving rate was investigated. Some suggestions on its practical manufacturing control were concluded based on the simulation results. 

This paper presents a simplified model for calculating the flow and temperature in laser transmission welding. The model was compiled on the basis of finite element analysis (FEA) and permits the comprehensive simulation of the process variants of contour welding, quasi-simultaneous welding and simultaneous welding. The model makes allowance for both the influence of the mechanical and thermal loading on the residual melt layer thickness and the temperature profiles in the joining seam. 

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