Simulation and analysis of three-dimensional polymer flow in injection moulding

A FDM-program for the simulation of three-dimensional flow during the metal die-casting process has been adapted to injection moulding. The polymer flow in areas with sudden wall thickness changes is calculated with the modified program. The results are compared to experiments with a special mould. This mould allows the flow-observation by a high-speed video camera from two different directions, so three-dimensional effects can be analyzed. Simulation and experiment show a good correspondance. In comparison to a regular two-dimensional, shell-element based simulation the flow front progress is predicted more accurately.