Numerical visualization of extensional flows in injection molding of polymer melts

Extensional flows generally take place in a channel with varied cross-sectional areas. During polymer processing with a variety of complex geometric features, it is difficult to separate extensional rates from shear rates in state-of-the-art predictive engineering tools of computational fluid dynamics. The recently proposed method of Tseng [Tseng, H.-C., “A Revisitation of Generalized Newtonian Fluids,” J Rheol 64 493–504 (2020)] decomposed the generalized strain rate as the characteristic shear and extensional rates via the rate-of-deformation tensor rotated along streamline coordinates. As validation for an isothermal center-gated disk flow, the predicted flow field profiles fairly matched the analytical solution for Newtonian fluid. Under injection molding simulations, an objective indicator is defined to visualize the colorful contours of extensional flows encountered in the gate-vicinity and the mid-plane of the cavity’s thickness direction, as well as contraction-expansion channels.

Flow-Fiber Coupled Viscosity in Injection Molding Simulations of Short Fiber Reinforced Thermoplastics

The main objective of this paper is to numerically investigate the use of fiber-dependent viscosity models in injection molding simulations of short fiber reinforced thermoplastics with latest commercial software. We propose to use the homogenization-based anisotropic rheological model to take into account flow-fiber coupling effects. The 4th-order viscosity tensor is approximated by an optimal scalar model and then implemented in the Moldflow Insight API framework. Numerical simulations are performed for a test-case rectangular plate with three fiber orientation models. The resulting coupled flow kinematics and fiber evolutions are then compared to the standard uncoupled simulations. Interpretations are given based on detailed post-processing of the field results. Certain deformation conditions are expected to be better taken into account, which may also in return lead to an improved fiber orientation prediction. Preliminary confrontation between flow-fiber coupled simulations and existing experimental data is then presented at the end of the paper.