Three‐dimensional finite element solution of gas‐assisted injection moulding

Abstract

Abstract This paper presents a finite element algorithm for solving gas‐assisted injection moulding problems. The filling material is considered incompressible and has temperature and shear rate dependent viscosity. The solution of the three‐dimensional (3D) equations modelling the momentum, mass and energy conservation is coupled with two front‐tracking equations, which are solved for the polymer/air and gas/polymer interfaces. The performances of the proposed procedure are quantified by solving the gas‐assisted injection problem on a thin plate with a flow channel. Solutions are shown for different polymer/gas ratios injected. The effect of the melt temperature, gas pressure and gas injection delay, on the solution behaviour is also investigated. The approach is then applied to a thick 3D part. Published in 2001 by John Wiley & Sons, Ltd.