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.