Abstract
AbstractA three‐dimensional transient finite element flow analysis code that includes inertia and free surface modeling is used to predict uniform (axisymmetric) and nonuniform (nonaxisymmetric) filling patterns in a thick‐walled tool with a diaphragm gate. The simulation for a metal injection molding compound, which is strongly influenced by thermal effects, predicted several observed flow patterns: initial annular free surface flow (jetting), bypass and folding flow to form surface defects, and the transition from uniform (axisymmetric) flow to nonuniform (nonaxisymmetric flow) with increasing fill time and lower temperatures. Simulations of filling through a thicker diaphragm gate showed jetting and the associated problems were eliminated. Simulations also demonstrate the effects of filling time, mold temperature, inertia, yield stress, and wall slip on filling patterns, particularly the processing conditions that separate regions of uniform and nonuniform flow.
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