Abstract
The governing equations of two-phase flows including gas and polymer melt are presented, which are solved using finite volume and domain extension methods with SIMPLEC technology. The melt filling and primary gas penetration in gas-assisted injection molding (GAIM) process are simulated, where the Cross-viscosity model is employed to describe the melt rheological behavior, and the CLSVOF(coupled Level Set and Volume of fluid) method is employed to capture the moving interfaces. In order to test and verify the coupled methods, melt filling in a rectangular plate with an insert is simulated, and the numerical results are in good agreement with those of the experiment. As a case study, the melt filling and gas penetration processes in a ring-shaped channel are simulated. The numerical results successfully depict some important phenomena, such as race-tracking effect, corner effect and the flow asymmetry of the gas penetration, which can deepen the understanding and studying of the GAIM process.
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