Abstract
The microcellular injection molding process is classified into short-shot process and full-shot process. Most current studies focus on short-shot process. In this paper, an algorithm for numerical simulation of full-shot microcellular injection molding is presented. The polymer-gas mixture in the cavity is treated as a macroscopic single-phase fluid. The unit cell model proposed by Amon and Denson is employed to model the cell growth, and the microscopic model of the cell growth is coupled with the macroscopic flow of polymer melt to describe the molding process. Governing equations involving the flow field and bubble growth are derived and solved iteratively. The effects of process parameters such as cell density and gas concentration on cell size are also investigated.
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