New boundary conditions for simulating the filling stage of the injection molding process

Purpose The purpose of this paper is to develop new boundary conditions for simulating the injection molding process of polymer melts. Design/methodology/approach The boundary conditions are derived and implemented to simulate real-life air vents (used to allow the air escape from the mold). The simulations are performed in the computational libraryOpenFOAM (R) by considering two different fluid models, namely, Newtonian and generalized Newtonian (Bird-Carreau model). Findings A detailed study on the accuracy of the solverinterFoamfor simulating the filling stage is presented, by considering simple geometries and adaptive mesh refinement. The verified code is then used to study the three-dimensional filling of a more complex geometry. Originality/value The results obtained showed that the numerical method is stable and allows one to model the filling process, simulating the real injection molding process.This work is funded by FEDER funds through the COMPETE 2020 Programme and National Funds through FCT (Portuguese Foundation for Science and Technology) under the projects UID-B/05256/2020, UID-P/05256/2020 and MOLDPRO-Aproximacoes multi-escala para moldacao por injecao de materiais plasticos (POCI-01-0145-FEDER-016665).The research of L.L. Ferras was partially financed by the Portuguese Funds through FCT within the Projects UID-B/00013/2020, UID-P/00013/2020 and the scholarship SFRH/BPD/100353/2014.The authors would like to acknowledge the Minho University Cluster (NORTE-07-0162-FEDER-000086) for providing the HPC resources that contributed to the research results reported within this paper