Injection Mold Flow Control Using Anisotropic Resin Viscosity
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Solution Overview
Problem
Current injection molding technologies face challenges in simulating complex flow fields and achieving numerical convergence in high flow rates due to the transient, non-Newtonian, and non-isothermal nature of polymer melts, particularly in 3D corner vortex simulations, where existing CAE tools fail to accurately decompose generalized strain rates into shear and extension rates and suffer from divergent issues.
Innovation Solution
The proposed solution involves generating an anisotropic viscosity distribution in the mold cavity based on the elastic effect of the molding resin, using a processing module to calculate the principal shear and extension rates, and an effective viscosity scalar, which is integrated into the governing equations to improve numerical convergence and simulate 3D corner vortex flows effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If generalized strain rate is used in CAE tools, then complex flow simulation is enabled, but decomposition into individual shear and extension rates is not achieved
Solution Approach 1:
The patent applies segmentation by decomposing the generalized strain rate into distinct shear rate and extension rate components through mathematical transformation of the velocity gradient tensor. This segmentation enables precise measurement and separate analysis of shear and extension deformations, improving measurement precision while maintaining the versatility of complex flow simulation.
2Manufacturing precision
If transient, non-Newtonian, and non-isothermal flow simulation is performed, then realistic polymer melt behavior is captured, but computational complexity and numerical instability increase
Solution Approach 1:
The patent transforms the complex non-Newtonian flow model into a more stable form by introducing the generalized strain rate decomposition and using it to define anisotropic viscosity. This parameter transformation maintains the accuracy of transient, non-Newtonian, and non-isothermal flow behavior while reducing numerical instability and managing computational complexity through a more robust mathematical framework.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the accuracy of injection molding simulations by stabilizing results at high flow rates and effectively simulating 3D corner vortex flows, addressing the numerical divergent issues in existing CAE tools and providing a more realistic representation of viscoelastic flow behaviors.
Implementation Method 1
a processing module configured to generate an anisotropic viscosity distribution of the molding resin in the mold cavity based on a molding condition for the molding machine, wherein the anisotropic viscosity distribution of the molding resin is generated based in part on an elastic effect of the molding resin
Implementation Method 2
the actual flow of polymer melts is transient, non-Newtonian and non-isothermal, with frozen layers building up as the complex mixture flows through the mold cavity
Data Source
AI summary
The present disclosure provides a molding system for preparing injection-molded articles. The molding system includes a molding machine; a mold disposed on the molding machine and having a mold cavity for being filled with a molding resin; a processing module configured to generate an anisotropic viscosity distribution of the molding resin in the mold cavity based on a molding condition for the molding machine, wherein the anisotropic viscosity distribution of the molding resin is generated based in part on an elastic effect of the molding resin; and a controller operably communicating with the processing module and configured to control the molding machine with the molding condition using the generated anisotropic viscosity distribution of the molding resin to perform an actual molding process for preparing the injection-molded article.