Numerical filling simulation of injection molding based on 3D finite element model

The traditional numerical simulation of injection molding is the 2.5D technique based on the Hele-Shaw approximation, which cannot predict the filling of thick or nonuniform-thickness parts and some flow behaviors such as the fountain flow. A three-dimensional (3D) finite element model is presented to perform more accurate simulations of a fully 3D flow. The model employs an equal-order velocity-pressure interpolation method. The relation between velocity and pressure is obtained from the discretized momentum equations in order to derive the pressure equation. A 3D control volume scheme is introduced to track the flow front. The validity of the model has been tested by case studies and experimental verification.