Abstract
The present study has numerically predicted both the flow -induced and thermally-induced residual stresses and birefringence in injection or injection/compression molded center -gated disks. Analysis system for entire molding process was developed based on an appropriate physical modeling including a nonlinear viscoelastic fluid model. stress-optical law. a linear viscoelastic solid model, free volume theory for density relaxation phenomena and a photoviscoelasticity and so on. Part I presents physical modeling and typical numerical analysis results of residual stresses and birefringence in the injection molded center -gated disk. Thermal residual stress was found to be extensional near the center, compressive near the surface and tend to become toward tensional at the surface. A double-hump profile was obtained across the thickness in birefringence distribution: nonzero birefringence is found to be thermally induced. the outer peak is due to the shear flow and subsequent stress relaxation during the filling stage and the inner peak is due to the additional shear flow and stress relaxation during the packing stage. Predicted birefringence including both the flow -induced and thermally-induced one becomes quite similar to the experimental one.
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