Abstract
This work investigates crystallization modeling by modifying an open-source computational fluid dynamics code OpenFOAM. The crystallization behavior of high-density polyethylene (HDPE) is implemented according to theoretical and experimental literature. A number of physical interdependencies are included. The cavity is modeled as deformable. The heat transfer coefficient in the thermal contact towards the mold depends on contact pressure. The thermal conductivity is pressure- and crystallinity-dependent. Specific heat depends on temperature and crystallinity. Latent heat is released according to the crystallization progress and temperature. Deviatoric elastic stress is evolved in the solidified material. The prediction of the cavity pressure evolution is used for the assessment of the solution quality because it is experimentally available and governs the residual stress development. Insight into the thermomechanical conditions is provided with through-thickness plots of pressure, temperature and cooling rate at different levels of crystallinity. The code and simulation setup are made openly available to further the research on the topic.
Highlights
Injection molding simulation research requires a considerably advanced computer code, which is true when including crystallization modeling
This work investigates crystallization modeling by modifying an open-source computational fluid dynamics code OpenFOAM
The constitutive modeling was advanced with an advanced viscoelastic material model by Chang and Chiou [3], a three-dimensional finite volume method was applied [4] and residual stresses were analyzed both experimentally and numerically for amorphous and crystalline polymers [5]—Guevara-Morales and Figueroa-López [6] published a thorough review of the research on the residual stresses
Summary
Injection molding simulation research requires a considerably advanced computer code, which is true when including crystallization modeling. Injection molding simulation has been the subject of ongoing research for decades. Kennedy and Zheng [1] have thoroughly reviewed the history of injection molding simulation publications. Based on the aim of predicting part geometry, the research was focused on the residual stress prediction. An important publication was contributed by Baaijens [2] who developed a model capable of describing the filling and packing stages as well as the final residual stresses. They highlighted the effect of mold compliance on the cavity pressure evolution. The constitutive modeling was advanced with an advanced viscoelastic material model by Chang and Chiou [3], a three-dimensional finite volume method was applied [4] and residual stresses were analyzed both experimentally and numerically for amorphous and crystalline polymers [5]—Guevara-Morales and Figueroa-López [6] published a thorough review of the research on the residual stresses
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