快速热循环注塑成型过程数值模拟方法研究
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摘要
快速热循环注塑(Rapid heat cycle molding,RHCM)是近年来兴起的一种塑料成型新技术。该技术在注射之前将模具型腔快速加热到塑料的玻璃化转变温度以上,以抑制熔体的过早冷凝,降低熔体的流动阻力,提高塑料熔体的充模流动能力。充填、保压后的快速冷却过程能够在较短时间内将成型后的塑件快速冷却到顶出温度以下,以缩短塑件成型周期,提高注塑生产效率。RHCM注塑新技术能够一次成型表面高光且没有熔接痕的塑料制品,消除了常规注塑(Conventional injection molding, CIM)中对环境污染严重的抛光和喷涂等二次加工工艺,真正实现了绿色注塑,具有广阔的应用前景。
RHCM注塑是一个相当复杂的物理过程,涉及高分子物理学、流变学、传热学和流体力学等多个学科的知识,其成型机理有待进一步探究。传统的理论分析和单纯的实验研究不足以解决这一复杂的物理问题。日益发展的数值模拟方法和计算机技术为人们解决多学科交叉的复杂物理问题和工程问题提供了强有力的研究手段。但是,采用传统注塑模拟方法进行RHCM注塑过程数值模拟尚存在诸多难点和问题。商业软件模具热响应分析的结果无法应用到RHCM注塑过程的熔体流动分析中,施加固定型腔温度的常规注塑模拟方法忽略了瞬态变化的RHCM注塑模具温度对充填和保压过程中熔体温度场以及流动状态的影响,其分析结果将导致熔体温度场和流场失真。传统的注塑冷却分析多采用周期平均温度代替模具内各点的温度,忽略了模具温度的周期性变化,难以反映瞬态变化的模具温度对RHCM注塑快速冷却过程的影响。传统的注塑模拟方法将模具和熔体孤立开,无法获得不同注塑循环中模具温度场的变化规律,难以实现多循环RHCM注塑过程的瞬态模拟。开发适合于模具温度瞬态变化的RHCM注塑过程的数值模拟技术,有助于揭示RHCM注塑技术的成型机理,通过数值模拟能够发现RHCM注塑模具结构及其成型工艺中存在的问题,提出改进方案,为RHCM注塑成型生产实际提供指导。因此,研究快速热循环注塑成型过程数值模拟理论与方法,具有重要的理论价值和工程意义。
本文开展了RHCM注塑过程数值模拟方法及其关键技术研究,针对RHCM注塑过程中模具温度瞬态变化的特点,研究了耦合模具传热的RHCM注塑过程数值模拟方法,分别建立了快速加热、充填、保压和快速冷却过程的数学模型,开发了各成型阶段的数值模拟程序,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑快速加热、充填、保压和快速冷却过程,获得了RHCM注塑过程中熔体速度场、压力场、温度场、密度场以及模具温度场等重要场变量的分布特点及其变化规律。通过集成RHCM注塑过程各阶段的数学模型及其数值模拟程序建立了快速热循环注塑过程瞬态模拟系统,实现了多循环RHCM注塑过程的三维瞬态模拟。建立了电加热式RHCM注塑实验线,采用数值模拟和实验的方法研究了多循环电加热式RHCM注塑过程,获得了不同加热/冷却循环下模具温度场的分布规律,研究了注射前电加热时间对熔体充模能力、充填状态以及熔接痕的微观形貌和力学性能的影响规律,数值模拟结果与电加热式RHCM注塑实验结果吻合良好,验证了本文开发的RHCM注塑过程三维瞬态模拟系统的准确性和可靠性。
本文基于Linux系统下的开源C++平台OpenFOAM,采用有限体积法离散控制方程和求解离散后的代数方程组,在简单介绍计算流体力学基本控制方程和有限体积法基本理论的基础上,推导了通用控制方程中瞬态项、对流项、扩散项和源项的离散过程,研究了离散后代数方程组的求解方法,为RHCM注塑过程快速加热、充填、保压和快速冷却阶段数值模拟程序的开发打下了理论基础。
快速加热过程是RHCM技术的关键环节,加热后的模具温度场分布是充填分析的初始条件,开展快速加热过程数值模拟将为RHCM注塑充填、保压和冷却过程中的模具温度场分析提供程序平台。本文建立了RHCM注塑快速加热过程模具热响应分析模型,根据电加热式和蒸汽加热式RHCM注塑模具内部无热源的特点,确定了模具-空气边界的自然对流换热、模具-电热棒边界的固定热流密度以及模具-加热蒸汽边界的强制对流换热边界条件模型,开发了RHCM注塑快速加热过程模具热响应分析程序,通过数值模拟获得了电加热和蒸汽加热过程中模具温度场的分布特点及其变化规律,模拟结果与商业软件ANSYS的热分析结果吻合良好,验证了本文热分析模型的有效性。
为了解决中面流法和双面流法不能分析变厚度和厚壁制件熔体流动的问题,本文将厚度方向速度与其它方向速度置于同等地位,建立了描述聚合物熔体三维非等温不可压缩充填流动的数学模型,采用PISO (Pressure Implicit with Splitting of Operators)算法求解耦合的速度场和压力场,基于VOF (Volume of Fluid)方法追踪熔体的流动前沿。为了解决VOF方法中流体体积函数迁移问题,建立了引入人工压缩项的流体体积函数输运方程。在型腔边界的处理上,为了解决简单地施加无滑移边界条件所引起的流动前沿失真问题,建立了以边界单元充填状态为判据的动态边界条件,根据边界单元流体体积函数取值的不同来实现无滑移边界条件(对于熔体)和自由穿梭边界条件(对于空气)的动态转换。开发了熔体充填流动过程数值分析程序。模拟研究了充填过程中熔体温度、速度和压力等场量的分布规律,对比了不同模具温度边界下熔体充填流动的特点,获得了型腔温度对熔体充填过程的影响规律,模拟结果与文献结果以及商业软件Moldflow的分析结果吻合良好,验证了本文开发的熔体三维流动过程数值模拟程序的可行性和正确性
针对常规流动模拟因忽略模具温度变化而引起的RHCM注塑充填分析结果失真问题,本文提出了耦合模具传热的注塑模拟方法,建立了耦合模具传热的RHCM注塑充填过程数学模型,在型腔区域内求解熔体流动过程的质量、动量守恒方程,获得熔体的速度场、压力场和应力应变场分布,在模具本体及其包围的型腔区域内同时求解模具的热传导方程和熔体流动的能量守恒方程,获得包括模具和熔体在内的整个系统的温度场分布,研究了模具-熔体耦合边界的处理方法,开发了耦合模具传热的RHCM注塑充填过程数值模拟程序。以快速加热过程模具热响应分析的结果为初始条件,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑的充填流动过程,揭示了充填过程中熔体的流动前沿状态、流场分布特点以及包括模具和熔体在内的整个系统温度场的分布规律,对比了固定边界温度充填分析和耦合模具传热充填分析结果的不同。模拟结果表明,考虑模具温度瞬态变化对熔体流动影响的耦合模具传热的充填分析程序更适合于RHCM注塑充填过程的数值模拟。
在保压过程中,熔体的密度变化较大,熔体的可压缩性不可忽略。针对保压过程的可压缩流动问题,本文建立了耦合模具传热的RHCM注塑保压过程数学模型,在型腔内部,用单域的Spencer-Gilmore状态方程描述熔体的可压缩性,基于PISO方法求解保压过程可压缩熔体的流动方程,获得熔体的流场和密度场分布,用引入人工压缩项的VOF输运方程追踪熔体的流动前沿。在模具本体及其包围的模具型腔内同时求解模具的热传导方程和熔体流动的能量守恒方程,获得模具和熔体的瞬态温度场分布,开发了耦合模具传热的RHCM注塑保压过程数值模拟程序。以充填分析终了时模具温度场分布以及型腔内塑料熔体的流场和温度场分布作为保压分析的初始条件,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑的保压过程,揭示了RHCM注塑保压过程中熔体温度场、密度场以及模具温度场的变化规律。
常规注塑冷却模拟多用周期平均温度代替模具内各点的温度,无法实现对RHCM注塑冷却过程的瞬态模拟。本文研究了模具与熔体间、模具与冷却剂间以及模具与空气间的热交换模型,建立了耦合模具传热的RHCM注塑快速冷却过程的数学模型,给出了描述冷却过程中模具内温度场变化的热传导方程,建立了型腔内熔体的质量守恒、动量守恒和能量守恒方程,考虑了体积力(重力)对冷却过程中熔体状态的影响,考虑了熔体固化潜热对冷却过程温度场的影响。为了研究快速冷却阶段熔体的凝固和收缩,基于Darcy定律建立了熔体凝固过程中两相区内已凝固塑料与未凝固熔体之间的关系,开发了耦合模具传热的RHCM注塑快速冷却过程数值模拟程序。以保压分析的结果为初始条件,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑的快速冷却过程,揭示了快速冷却过程中模具温度场变化、熔体的凝固现象、温度场分布、密度场分布以及塑件的收缩规律。
常规注塑模拟方法忽略了注塑过程中熔体和模具间的耦合传热,无法实现多循环RHCM注塑过程的瞬态模拟。针对这一问题,本文通过集成RHCM注塑快速加热、充填、保压和快速冷却过程的数学模型及其数值模拟程序,开发了多循环RHCM注塑过程瞬态模拟系统,该系统以模具热响应分析的结果为初始条件进行耦合模具传热的熔体充填和保压过程数值模拟,将充填／保压模拟获得的熔体流场、温度场以及模具温度场分布作为冷却过程的初始条件,进行耦合模具传热的RHCM注塑快速冷却过程数值模拟,在多循环注塑过程中,把上一个RHCM注塑循环的模拟结果作为下一个RHCM注塑循环的初始条件,实现了多循环RHCM注塑过程的三维瞬态数值模拟。
自主开发了基于电加热和水冷却的RHCM注塑模具温度控制系统以及电加热模具。采用数值模拟和实验相结合的方法,研究了多循环电加热式RHCM注塑过程,获得了不同加热／冷却循环次数下的模具温度场分布规律,研究了注射前电加热时间对熔体充模能力和充填状态的影响规律,基于电加热式RHCM注塑实验,研究了注射前电加热时间对双浇口试样熔接痕形貌及其力学性能的影响。模拟结果与电加热式RHCM定压充填实验和短射实验结果吻合良好,验证了本文开发的多循环RHCM注塑过程瞬态模拟系统的准确性和可靠性。
Rapid heat cycle molding (RHCM) is a new plastic processing technology raised in recent years. In RHCM process, mold cavity is rapidly heated to a high temperature before injection, usually higher than the glass transition temperature of the polymer. Since the elevated mold temperature can eliminate the unwanted premature melt freezing during filling stage, melt flow resistance is greatly reduced and the filling ability of the polymer melt is also significantly improved. This heated mold cavity needs to be rapidly cooled after filling and packing to maintain a short cycle time. RHCM new technology can produce plastic parts with glossary surface and without weld lines. The re-processing operations including spraying and coating in conventional injection molding (CIM) process are eliminated in RHCM technology, which makes truly green injection molding process to be available.
RHCM technology is a very complex physical process, involving polymer physics, rheology, heat transfer, fluid mechanics and other related disciplines, its forming mechanism needs further exploration. Traditional theoretical analysis and pure experimental study are not enough to solve this complex physical problem. With the development of calculation method and computer technology, numerical analysis method becomes a powerful tool to solve complex multidisciplinary physical and engineering problems. However, traditional injection molding simulation method meets many difficulties and probles when analylizes the RHCM process. Thermal analysis results by business software can not be applied to melt filling simulation in RHCM process. Conventional injection molding simulation methods ignore the effects of temperature varations in RHCM mold on the temperature and filling state of polymer melt in filling and packing processes. And the analysis results will lead to distortions of melt temperature and flow fields. Traditional cooling methods usually use the cycle averaged temperature instead of transient mold temperature, and varations of mold temperatue during different molding cycles are neglected. As a result, it is diffcult to reflect the effects of transient mold temperature on RHCM rapid cooling process. Mold and melt are isolated in conventional injection molding simulation methods. Mold temperature varations in multi-cycle RHCM process can not be predicted. Therefore, it is impossible for conventional injection molding simulation methods to achieve transient analysis in multi-cycle RHCM process. Developing numerical methods considering the transiently changed mold temperature in RHCM process has great significance in theory and practice. It is helpful to reveal the mechanism of RHCM technique. Numerical analysis can predict irrational mold structures and forming parameters prior to actual productions, and provide valuable guidance for actual RHCM productions.
This paper focus on numerical methods and its key techniques for RHCM processes. A simulation method coupled with mold heat transfer was proposed accorded to the changeable mold temperature in RHCM process. The mathematical models for rapid heating, melt filling, packing and rapid cooling stages in RHCM process were established. And the corresponding numerical analysis programs were developed. Principles for the distributions and variations of melt velocity, melt pressure, melt temperature, mold temperature and other important characteristics were gained. A rapid heat cycle molding transient simulation system was developed by integrating the various stages RHCM mathematical model and numerical analysis procedures. Three-dimensional transient simulation for multi-cycle RHCM process was achieved. An RHCM experimental system with electric heating and water cooling was established. Multi-cycle electric heated RHCM forming processes were numerically and experimentally studied. And the princples of mold temperature distributions during different RHCM cycles were gained. Effects of electric heating time before injection on melt filling ability, filling state, weld line micro structure and its mechnical properties were invesgated. Numerical results were consistent with the experimental results in RHCM process with electric heating. And the accuracy and reliability of the simulation system developed in this paper were verified.
The open source C++liberies OpenFOAM on Linux system and finite volume method were used in current paper to discrete the governing equations and solve the subsequent algebric equations. Basic theories of computational fluid dynamics and finite volume method were described. Discretization processes for the transient, convection, diffusion and source terms in generic transport equation were derived in detail. And solution methods for the algebraic equations after discretization were discussed. Discretization and solution methods for general governing equation lay a theoretical foundation for the development of numerical simulation program for the rapid heating, melt filling, packing and rapid cooling stages in RHCM molding process.
Rapid heating process plays an important role in RHCM technology. Mold temperature field after heating is the initial condition for melt filling simulation. Developing rapid heating simulation procedure will supply a program platform for mold temperature analysis in filling, packing and cooling stages of RHCM process. The transient thermal response model for RHCM mold was established and its numerical procedure was developed. Natural convection heat transfer on mold-air boundary, fixed heat flux on mold-electric rod boundary and forced convection heat transfer on mold-steam boundary were established according to the characteristics of electric heating and steam heating processes. Mold temperature distributions and its variations in electric heating and steam heating processed were gained by transient thermal response analysis. Numerical results agreed well with the thermal analysis results by ANSYS.
Traditional middle-plane and dual domain techniques, in which the velocity component in the gapwise direction is neglected, can not analyze melt flow process in thick-walled work piece or plastic part with variable thickness. In order to solve this problem, the velocity component in the gapwise direction was considered in the current paper. Mathematical model and its numerical procedure for three-dimensional, non-isothermal, impressible melt filling flow process were presented. The pressure implicit with splitting of operators (PISO) method was adopted to solve the coupled velocity and pressure field. The volume of fluid (VOF) method was used to capture melt flow front. For the purpose of avoiding the migration of volume fraction, an artificial compression term was introduced in VOF transport equation. The imposing of slip or no-slip boundary condition at the mold boundaries will result in unrealistic interface predictions. A dynamic boundary condition was presented in the current research to solve the aforementioned problem. No-slip (for melt) and traction free (for air) boundary conditions were switched dynamically according to the filling status of the boundary cells. Temperature, velocity and pressure distributions in melt filling process were numerically researched. Melt flow characteristics with different mold temperatures were compared, and the influence of mold temperature on melt flow process was accessed. Numerical results show good agreement with literature and analytical results by commercial software Moldflow, which validates the feasibility and correctness of the developed program.
Conventional filling simulation methods usually apply a constant temperature boundary condition on mold cavity. Ignoring the effects of variable mold temperature on melt flow will lead to distorted melt temperature and flow field predictions in RHCM filling process. An idea coupled with mold heat transfer in melt flow simulation was proposed in this paper. Mathematical model and its numerical procedure were developed in RHCM filling process. Mass and momentum conservation equations were solved in cavity region to gain melt velocity and pressure distributions, while the heat transfer equation for mold and energy conservation equation for melt were solved in a coupled manner on the mold and cavity domains, and temperature distributions for both mold and melt were calculated. Boundary conditions on the coupled mold-melt surface were established. Two-dimensional electric heated and three-dimensional steam heated RHCM filling processes were numerically investigated by implying analytical results in rapid thermal response as initial mold temperature conditions. Melt flow fronts, flow field distributions and temperature field distributions for mold and melt in RHCM filling process were revealed. Differences between analytical results by conventional filling simulation with constant boundary conditions and coupled filling simulation were compared. The results show that the coupled method considering mold temperature variations is more suitable for melt filling simulation in RHCM process.
Compressibility of melt is great and can not be ignored in packing process. Mathematical model and its numerical procedure were developed for RHCM packing process coupled with mold heat transfer. Single-domain Spencer-Gilmore state equation was used to describe the compressibility of polymer melt in RHCM packing stage. The coupled velocity and pressure in compressible melt flow equation were solved using PISO method. Flow field and density field of polymer melt were gained. The VOF method with artificial compression term was used to capture melt flow front. Temperature distributions for both mold and melt were solved in a coupled manner. Two-dimensional electric heated and three-dimensional steam heated RHCM packing processes were numerically investigated by implying analytical results in filling simulation as initial conditions. Temperature, density distributions for polymer melt and temperature distributions for mold in RHCM packing process were revealed.
It is difficult for conventional simulation methods to simulate the transient cooling stage in RHCM process by using cycle-averaged mold temperature. Heat transfer models between mold and melt, mold coolant, mold and air were presented in this paper. Mathematical model and its numerical procedure were developed for RHCM cooling process coupled with mold heat transfer. Mass, momentum, energy conservation equations for polymer melt and heat transfer equation for mold were established. The body force (gravity) and latent heat during melt solidification were considered. In order to investigate melt solidification and shrinkage phenomena in rapid cooling process, relations between solidified polymer and polymer melt were established based on Darcy's law. Two-dimensional electric heated and three-dimensional steam heated RHCM rapid cooling processes were numerically investigated by implying analytical results in packing simulation as initial conditions. Solidification, shrinkage, temperature and density distributions for polymer melt and temperature distributions for mold in RHCM rapid cooling process were revealed.
Conventional injection molding simulation methods, in which the changes of mold temperature are ignored, can not be used to simulate multi-cycle RHCM process. In order to solve this problem, a rapid heat cycle molding simulation system was developed by integrating the various stages RHCM mathematical model and numerical analysis procedures presented in this paper. Numerical results in mold thermal response analysis were implied as initial boundary conditions for melt filling and packing simulations. And the distributions of melt flow filed, temperature and mold temperature after filling and packing were used as intal conditions in cooling stage. The numerical results for former RHCM cycle were used as initial boundary conditions in simulation of next RHCM cycle. As a result, three-dimensional transient simulation for multi-cycle RHCM process was achieved.
Temperature control system and electric heating mold developed by our lab were linked with plastic machine to construct RHCM injection system. Multi-cycle electric heated RHCM processes were investigated using the developed transient RHCM simulation system combined with experimental study. Mold temperature distributions during different heating and cooling cycles were founded. Effects of electric heating time before injection on melt flow ability and its filling state were revealed. Influences of electric heating time on morphology and mechanical properties of weld line in double gated plastic parts were experimentally investigated. Numerical results by the developed transient RHCM simulation system were consistent with the experimental results in electric heated RHCM process. Therefore, the accuracy and reliability of the simulation system developed in this paper were verified.
RHCM注塑是一个相当复杂的物理过程,涉及高分子物理学、流变学、传热学和流体力学等多个学科的知识,其成型机理有待进一步探究。传统的理论分析和单纯的实验研究不足以解决这一复杂的物理问题。日益发展的数值模拟方法和计算机技术为人们解决多学科交叉的复杂物理问题和工程问题提供了强有力的研究手段。但是,采用传统注塑模拟方法进行RHCM注塑过程数值模拟尚存在诸多难点和问题。商业软件模具热响应分析的结果无法应用到RHCM注塑过程的熔体流动分析中,施加固定型腔温度的常规注塑模拟方法忽略了瞬态变化的RHCM注塑模具温度对充填和保压过程中熔体温度场以及流动状态的影响,其分析结果将导致熔体温度场和流场失真。传统的注塑冷却分析多采用周期平均温度代替模具内各点的温度,忽略了模具温度的周期性变化,难以反映瞬态变化的模具温度对RHCM注塑快速冷却过程的影响。传统的注塑模拟方法将模具和熔体孤立开,无法获得不同注塑循环中模具温度场的变化规律,难以实现多循环RHCM注塑过程的瞬态模拟。开发适合于模具温度瞬态变化的RHCM注塑过程的数值模拟技术,有助于揭示RHCM注塑技术的成型机理,通过数值模拟能够发现RHCM注塑模具结构及其成型工艺中存在的问题,提出改进方案,为RHCM注塑成型生产实际提供指导。因此,研究快速热循环注塑成型过程数值模拟理论与方法,具有重要的理论价值和工程意义。
本文开展了RHCM注塑过程数值模拟方法及其关键技术研究,针对RHCM注塑过程中模具温度瞬态变化的特点,研究了耦合模具传热的RHCM注塑过程数值模拟方法,分别建立了快速加热、充填、保压和快速冷却过程的数学模型,开发了各成型阶段的数值模拟程序,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑快速加热、充填、保压和快速冷却过程,获得了RHCM注塑过程中熔体速度场、压力场、温度场、密度场以及模具温度场等重要场变量的分布特点及其变化规律。通过集成RHCM注塑过程各阶段的数学模型及其数值模拟程序建立了快速热循环注塑过程瞬态模拟系统,实现了多循环RHCM注塑过程的三维瞬态模拟。建立了电加热式RHCM注塑实验线,采用数值模拟和实验的方法研究了多循环电加热式RHCM注塑过程,获得了不同加热/冷却循环下模具温度场的分布规律,研究了注射前电加热时间对熔体充模能力、充填状态以及熔接痕的微观形貌和力学性能的影响规律,数值模拟结果与电加热式RHCM注塑实验结果吻合良好,验证了本文开发的RHCM注塑过程三维瞬态模拟系统的准确性和可靠性。
本文基于Linux系统下的开源C++平台OpenFOAM,采用有限体积法离散控制方程和求解离散后的代数方程组,在简单介绍计算流体力学基本控制方程和有限体积法基本理论的基础上,推导了通用控制方程中瞬态项、对流项、扩散项和源项的离散过程,研究了离散后代数方程组的求解方法,为RHCM注塑过程快速加热、充填、保压和快速冷却阶段数值模拟程序的开发打下了理论基础。
快速加热过程是RHCM技术的关键环节,加热后的模具温度场分布是充填分析的初始条件,开展快速加热过程数值模拟将为RHCM注塑充填、保压和冷却过程中的模具温度场分析提供程序平台。本文建立了RHCM注塑快速加热过程模具热响应分析模型,根据电加热式和蒸汽加热式RHCM注塑模具内部无热源的特点,确定了模具-空气边界的自然对流换热、模具-电热棒边界的固定热流密度以及模具-加热蒸汽边界的强制对流换热边界条件模型,开发了RHCM注塑快速加热过程模具热响应分析程序,通过数值模拟获得了电加热和蒸汽加热过程中模具温度场的分布特点及其变化规律,模拟结果与商业软件ANSYS的热分析结果吻合良好,验证了本文热分析模型的有效性。
为了解决中面流法和双面流法不能分析变厚度和厚壁制件熔体流动的问题,本文将厚度方向速度与其它方向速度置于同等地位,建立了描述聚合物熔体三维非等温不可压缩充填流动的数学模型,采用PISO (Pressure Implicit with Splitting of Operators)算法求解耦合的速度场和压力场,基于VOF (Volume of Fluid)方法追踪熔体的流动前沿。为了解决VOF方法中流体体积函数迁移问题,建立了引入人工压缩项的流体体积函数输运方程。在型腔边界的处理上,为了解决简单地施加无滑移边界条件所引起的流动前沿失真问题,建立了以边界单元充填状态为判据的动态边界条件,根据边界单元流体体积函数取值的不同来实现无滑移边界条件(对于熔体)和自由穿梭边界条件(对于空气)的动态转换。开发了熔体充填流动过程数值分析程序。模拟研究了充填过程中熔体温度、速度和压力等场量的分布规律,对比了不同模具温度边界下熔体充填流动的特点,获得了型腔温度对熔体充填过程的影响规律,模拟结果与文献结果以及商业软件Moldflow的分析结果吻合良好,验证了本文开发的熔体三维流动过程数值模拟程序的可行性和正确性
针对常规流动模拟因忽略模具温度变化而引起的RHCM注塑充填分析结果失真问题,本文提出了耦合模具传热的注塑模拟方法,建立了耦合模具传热的RHCM注塑充填过程数学模型,在型腔区域内求解熔体流动过程的质量、动量守恒方程,获得熔体的速度场、压力场和应力应变场分布,在模具本体及其包围的型腔区域内同时求解模具的热传导方程和熔体流动的能量守恒方程,获得包括模具和熔体在内的整个系统的温度场分布,研究了模具-熔体耦合边界的处理方法,开发了耦合模具传热的RHCM注塑充填过程数值模拟程序。以快速加热过程模具热响应分析的结果为初始条件,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑的充填流动过程,揭示了充填过程中熔体的流动前沿状态、流场分布特点以及包括模具和熔体在内的整个系统温度场的分布规律,对比了固定边界温度充填分析和耦合模具传热充填分析结果的不同。模拟结果表明,考虑模具温度瞬态变化对熔体流动影响的耦合模具传热的充填分析程序更适合于RHCM注塑充填过程的数值模拟。
在保压过程中,熔体的密度变化较大,熔体的可压缩性不可忽略。针对保压过程的可压缩流动问题,本文建立了耦合模具传热的RHCM注塑保压过程数学模型,在型腔内部,用单域的Spencer-Gilmore状态方程描述熔体的可压缩性,基于PISO方法求解保压过程可压缩熔体的流动方程,获得熔体的流场和密度场分布,用引入人工压缩项的VOF输运方程追踪熔体的流动前沿。在模具本体及其包围的模具型腔内同时求解模具的热传导方程和熔体流动的能量守恒方程,获得模具和熔体的瞬态温度场分布,开发了耦合模具传热的RHCM注塑保压过程数值模拟程序。以充填分析终了时模具温度场分布以及型腔内塑料熔体的流场和温度场分布作为保压分析的初始条件,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑的保压过程,揭示了RHCM注塑保压过程中熔体温度场、密度场以及模具温度场的变化规律。
常规注塑冷却模拟多用周期平均温度代替模具内各点的温度,无法实现对RHCM注塑冷却过程的瞬态模拟。本文研究了模具与熔体间、模具与冷却剂间以及模具与空气间的热交换模型,建立了耦合模具传热的RHCM注塑快速冷却过程的数学模型,给出了描述冷却过程中模具内温度场变化的热传导方程,建立了型腔内熔体的质量守恒、动量守恒和能量守恒方程,考虑了体积力(重力)对冷却过程中熔体状态的影响,考虑了熔体固化潜热对冷却过程温度场的影响。为了研究快速冷却阶段熔体的凝固和收缩,基于Darcy定律建立了熔体凝固过程中两相区内已凝固塑料与未凝固熔体之间的关系,开发了耦合模具传热的RHCM注塑快速冷却过程数值模拟程序。以保压分析的结果为初始条件,模拟研究了二维电加热式和三维蒸汽加热式RHCM注塑的快速冷却过程,揭示了快速冷却过程中模具温度场变化、熔体的凝固现象、温度场分布、密度场分布以及塑件的收缩规律。
常规注塑模拟方法忽略了注塑过程中熔体和模具间的耦合传热,无法实现多循环RHCM注塑过程的瞬态模拟。针对这一问题,本文通过集成RHCM注塑快速加热、充填、保压和快速冷却过程的数学模型及其数值模拟程序,开发了多循环RHCM注塑过程瞬态模拟系统,该系统以模具热响应分析的结果为初始条件进行耦合模具传热的熔体充填和保压过程数值模拟,将充填／保压模拟获得的熔体流场、温度场以及模具温度场分布作为冷却过程的初始条件,进行耦合模具传热的RHCM注塑快速冷却过程数值模拟,在多循环注塑过程中,把上一个RHCM注塑循环的模拟结果作为下一个RHCM注塑循环的初始条件,实现了多循环RHCM注塑过程的三维瞬态数值模拟。
自主开发了基于电加热和水冷却的RHCM注塑模具温度控制系统以及电加热模具。采用数值模拟和实验相结合的方法,研究了多循环电加热式RHCM注塑过程,获得了不同加热／冷却循环次数下的模具温度场分布规律,研究了注射前电加热时间对熔体充模能力和充填状态的影响规律,基于电加热式RHCM注塑实验,研究了注射前电加热时间对双浇口试样熔接痕形貌及其力学性能的影响。模拟结果与电加热式RHCM定压充填实验和短射实验结果吻合良好,验证了本文开发的多循环RHCM注塑过程瞬态模拟系统的准确性和可靠性。
Rapid heat cycle molding (RHCM) is a new plastic processing technology raised in recent years. In RHCM process, mold cavity is rapidly heated to a high temperature before injection, usually higher than the glass transition temperature of the polymer. Since the elevated mold temperature can eliminate the unwanted premature melt freezing during filling stage, melt flow resistance is greatly reduced and the filling ability of the polymer melt is also significantly improved. This heated mold cavity needs to be rapidly cooled after filling and packing to maintain a short cycle time. RHCM new technology can produce plastic parts with glossary surface and without weld lines. The re-processing operations including spraying and coating in conventional injection molding (CIM) process are eliminated in RHCM technology, which makes truly green injection molding process to be available.
RHCM technology is a very complex physical process, involving polymer physics, rheology, heat transfer, fluid mechanics and other related disciplines, its forming mechanism needs further exploration. Traditional theoretical analysis and pure experimental study are not enough to solve this complex physical problem. With the development of calculation method and computer technology, numerical analysis method becomes a powerful tool to solve complex multidisciplinary physical and engineering problems. However, traditional injection molding simulation method meets many difficulties and probles when analylizes the RHCM process. Thermal analysis results by business software can not be applied to melt filling simulation in RHCM process. Conventional injection molding simulation methods ignore the effects of temperature varations in RHCM mold on the temperature and filling state of polymer melt in filling and packing processes. And the analysis results will lead to distortions of melt temperature and flow fields. Traditional cooling methods usually use the cycle averaged temperature instead of transient mold temperature, and varations of mold temperatue during different molding cycles are neglected. As a result, it is diffcult to reflect the effects of transient mold temperature on RHCM rapid cooling process. Mold and melt are isolated in conventional injection molding simulation methods. Mold temperature varations in multi-cycle RHCM process can not be predicted. Therefore, it is impossible for conventional injection molding simulation methods to achieve transient analysis in multi-cycle RHCM process. Developing numerical methods considering the transiently changed mold temperature in RHCM process has great significance in theory and practice. It is helpful to reveal the mechanism of RHCM technique. Numerical analysis can predict irrational mold structures and forming parameters prior to actual productions, and provide valuable guidance for actual RHCM productions.
This paper focus on numerical methods and its key techniques for RHCM processes. A simulation method coupled with mold heat transfer was proposed accorded to the changeable mold temperature in RHCM process. The mathematical models for rapid heating, melt filling, packing and rapid cooling stages in RHCM process were established. And the corresponding numerical analysis programs were developed. Principles for the distributions and variations of melt velocity, melt pressure, melt temperature, mold temperature and other important characteristics were gained. A rapid heat cycle molding transient simulation system was developed by integrating the various stages RHCM mathematical model and numerical analysis procedures. Three-dimensional transient simulation for multi-cycle RHCM process was achieved. An RHCM experimental system with electric heating and water cooling was established. Multi-cycle electric heated RHCM forming processes were numerically and experimentally studied. And the princples of mold temperature distributions during different RHCM cycles were gained. Effects of electric heating time before injection on melt filling ability, filling state, weld line micro structure and its mechnical properties were invesgated. Numerical results were consistent with the experimental results in RHCM process with electric heating. And the accuracy and reliability of the simulation system developed in this paper were verified.
The open source C++liberies OpenFOAM on Linux system and finite volume method were used in current paper to discrete the governing equations and solve the subsequent algebric equations. Basic theories of computational fluid dynamics and finite volume method were described. Discretization processes for the transient, convection, diffusion and source terms in generic transport equation were derived in detail. And solution methods for the algebraic equations after discretization were discussed. Discretization and solution methods for general governing equation lay a theoretical foundation for the development of numerical simulation program for the rapid heating, melt filling, packing and rapid cooling stages in RHCM molding process.
Rapid heating process plays an important role in RHCM technology. Mold temperature field after heating is the initial condition for melt filling simulation. Developing rapid heating simulation procedure will supply a program platform for mold temperature analysis in filling, packing and cooling stages of RHCM process. The transient thermal response model for RHCM mold was established and its numerical procedure was developed. Natural convection heat transfer on mold-air boundary, fixed heat flux on mold-electric rod boundary and forced convection heat transfer on mold-steam boundary were established according to the characteristics of electric heating and steam heating processes. Mold temperature distributions and its variations in electric heating and steam heating processed were gained by transient thermal response analysis. Numerical results agreed well with the thermal analysis results by ANSYS.
Traditional middle-plane and dual domain techniques, in which the velocity component in the gapwise direction is neglected, can not analyze melt flow process in thick-walled work piece or plastic part with variable thickness. In order to solve this problem, the velocity component in the gapwise direction was considered in the current paper. Mathematical model and its numerical procedure for three-dimensional, non-isothermal, impressible melt filling flow process were presented. The pressure implicit with splitting of operators (PISO) method was adopted to solve the coupled velocity and pressure field. The volume of fluid (VOF) method was used to capture melt flow front. For the purpose of avoiding the migration of volume fraction, an artificial compression term was introduced in VOF transport equation. The imposing of slip or no-slip boundary condition at the mold boundaries will result in unrealistic interface predictions. A dynamic boundary condition was presented in the current research to solve the aforementioned problem. No-slip (for melt) and traction free (for air) boundary conditions were switched dynamically according to the filling status of the boundary cells. Temperature, velocity and pressure distributions in melt filling process were numerically researched. Melt flow characteristics with different mold temperatures were compared, and the influence of mold temperature on melt flow process was accessed. Numerical results show good agreement with literature and analytical results by commercial software Moldflow, which validates the feasibility and correctness of the developed program.
Conventional filling simulation methods usually apply a constant temperature boundary condition on mold cavity. Ignoring the effects of variable mold temperature on melt flow will lead to distorted melt temperature and flow field predictions in RHCM filling process. An idea coupled with mold heat transfer in melt flow simulation was proposed in this paper. Mathematical model and its numerical procedure were developed in RHCM filling process. Mass and momentum conservation equations were solved in cavity region to gain melt velocity and pressure distributions, while the heat transfer equation for mold and energy conservation equation for melt were solved in a coupled manner on the mold and cavity domains, and temperature distributions for both mold and melt were calculated. Boundary conditions on the coupled mold-melt surface were established. Two-dimensional electric heated and three-dimensional steam heated RHCM filling processes were numerically investigated by implying analytical results in rapid thermal response as initial mold temperature conditions. Melt flow fronts, flow field distributions and temperature field distributions for mold and melt in RHCM filling process were revealed. Differences between analytical results by conventional filling simulation with constant boundary conditions and coupled filling simulation were compared. The results show that the coupled method considering mold temperature variations is more suitable for melt filling simulation in RHCM process.
Compressibility of melt is great and can not be ignored in packing process. Mathematical model and its numerical procedure were developed for RHCM packing process coupled with mold heat transfer. Single-domain Spencer-Gilmore state equation was used to describe the compressibility of polymer melt in RHCM packing stage. The coupled velocity and pressure in compressible melt flow equation were solved using PISO method. Flow field and density field of polymer melt were gained. The VOF method with artificial compression term was used to capture melt flow front. Temperature distributions for both mold and melt were solved in a coupled manner. Two-dimensional electric heated and three-dimensional steam heated RHCM packing processes were numerically investigated by implying analytical results in filling simulation as initial conditions. Temperature, density distributions for polymer melt and temperature distributions for mold in RHCM packing process were revealed.
It is difficult for conventional simulation methods to simulate the transient cooling stage in RHCM process by using cycle-averaged mold temperature. Heat transfer models between mold and melt, mold coolant, mold and air were presented in this paper. Mathematical model and its numerical procedure were developed for RHCM cooling process coupled with mold heat transfer. Mass, momentum, energy conservation equations for polymer melt and heat transfer equation for mold were established. The body force (gravity) and latent heat during melt solidification were considered. In order to investigate melt solidification and shrinkage phenomena in rapid cooling process, relations between solidified polymer and polymer melt were established based on Darcy's law. Two-dimensional electric heated and three-dimensional steam heated RHCM rapid cooling processes were numerically investigated by implying analytical results in packing simulation as initial conditions. Solidification, shrinkage, temperature and density distributions for polymer melt and temperature distributions for mold in RHCM rapid cooling process were revealed.
Conventional injection molding simulation methods, in which the changes of mold temperature are ignored, can not be used to simulate multi-cycle RHCM process. In order to solve this problem, a rapid heat cycle molding simulation system was developed by integrating the various stages RHCM mathematical model and numerical analysis procedures presented in this paper. Numerical results in mold thermal response analysis were implied as initial boundary conditions for melt filling and packing simulations. And the distributions of melt flow filed, temperature and mold temperature after filling and packing were used as intal conditions in cooling stage. The numerical results for former RHCM cycle were used as initial boundary conditions in simulation of next RHCM cycle. As a result, three-dimensional transient simulation for multi-cycle RHCM process was achieved.
Temperature control system and electric heating mold developed by our lab were linked with plastic machine to construct RHCM injection system. Multi-cycle electric heated RHCM processes were investigated using the developed transient RHCM simulation system combined with experimental study. Mold temperature distributions during different heating and cooling cycles were founded. Effects of electric heating time before injection on melt flow ability and its filling state were revealed. Influences of electric heating time on morphology and mechanical properties of weld line in double gated plastic parts were experimentally investigated. Numerical results by the developed transient RHCM simulation system were consistent with the experimental results in electric heated RHCM process. Therefore, the accuracy and reliability of the simulation system developed in this paper were verified.
引文
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