3D numerical simulation of gas-assisted injection molding process

This paper presents a finite element algorithm for solving gas-assisted injection molding problems. The solution of the three-dimensional (3D) equations modeling 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 rib. Solutions are shown for different ratios polymer/gas injected. The effect of the melt temperature, gas pressure and gas injection delay, on the solution behavior is also investigated. The approach is then applied to a thick 3D part.