The reactive process of reinforced thermoset injection molding signiﬁcantly inﬂuences the mechanical properties of the ﬁnal composite structure. Therefore, reliable process simulation is crucial to predict the process behavior and relevant process effects. Virtual process design is thus highly important for the composite manufacturing industry for creating high quality parts. Although thermoset injection molding shows a more complex ﬂow behavior, state of the art molding
simulation software typically focusses on thermoplastic injection molding. To overcome this gap in virtual process prediction, the present work proposes a ﬁnite volume (FV) based simulation method, which models the multiphase ﬂow with phase-dependent boundary conditions. Compared to state-of-the-art Finite-Element-based approaches, Finite-Volume-Method (FVM) provides more adequate multiphase ﬂow modeling by calculating the ﬂow at the cell surfaces with an Eulerian approach. The new method also enables the description of a ﬂow region with partial wall contact.
Furthermore, ﬁber orientation, curing and viscosity models are used to simulate the reinforced reactive injection molding process. ... mehrThe open source Computational-Fluid-Dynamics (CFD) toolbox OpenFOAM is used for implementation. The solver is validated with experimental pressure data recorded during mold ﬁlling. Additionally, the simulation results are compared to commercial Finite-Element-Method software. The simulation results of the new FV-based CFD method ﬁt well with the experimental data, showing that FVM has a high potential for modeling reinforced reactive injection molding.