基于HCZ模型的注塑成型充填过程模拟
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摘要
塑料熔体充填过程中的微结构形态对注塑制品性能影响很大,是注塑制品控形、控性的基础,使用格子玻尔兹曼法(lattice Boltzmann method, LBM)中的HCZ(He-Chen-Zhang)模型能模拟注塑过程中复杂的多相流和微结构形态演化过程。通过开发HCZ模型的程序,模拟了模具型腔内熔体流动的Poiseuille流。研究表明,模拟结果与理论解基本吻合,验证了HCZ模型能准确地模拟塑料熔体的非线性流动行为。使用HCZ多相流模型模拟了注塑熔体充填和气辅成型气体穿透过程,模拟的注塑熔体流动前沿"喷泉效应"与实际成型过程相符,气辅成型气体压力不仅影响气道厚度,而且影响厚度的均匀性。
The microstructure in the filling stage has a great influence on the properties of injection moulding products, which is the basis of shape and performance control of injection moulding products. The complex multiphase flow and the microstructure evolution can be simulated through HCZ(He-Chen-Zhang) model of lattice Boltzmann method(LBM). According to HCZ model, a software was developed to simulate Poiseuille flow in mould cavity. The results show that the simulation results are in good agreement with the theoretical solutions, which verifies that the HCZ model can accurately simulate the non-linear flow behavior of plastic melt. HCZ multiphase flow model was also used to simulate the injection melt filling and gas penetration of gas-assisted injection moulding. The "fountain effect" in the front of the simulated melt flow was consistent with the actual injection process. The results show that gas pressure in gas-assisted injection molding not only affected the thickness of the airway, but also affected the uniformity of the thickness.
The microstructure in the filling stage has a great influence on the properties of injection moulding products, which is the basis of shape and performance control of injection moulding products. The complex multiphase flow and the microstructure evolution can be simulated through HCZ(He-Chen-Zhang) model of lattice Boltzmann method(LBM). According to HCZ model, a software was developed to simulate Poiseuille flow in mould cavity. The results show that the simulation results are in good agreement with the theoretical solutions, which verifies that the HCZ model can accurately simulate the non-linear flow behavior of plastic melt. HCZ multiphase flow model was also used to simulate the injection melt filling and gas penetration of gas-assisted injection moulding. The "fountain effect" in the front of the simulated melt flow was consistent with the actual injection process. The results show that gas pressure in gas-assisted injection molding not only affected the thickness of the airway, but also affected the uniformity of the thickness.
引文
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[2] 杨伟,武力军,李瑞文,等.物理微发泡微开模注塑成型技术[J].模具技术,2017(4):52-58.
[3] 杨安,肖国华,华明伟.模流数值分析与试模工艺参数实践设置计算[J].模具技术,2015(3):5-9.
[4] 尹红灵.基于CAE技术的汽车前面板注塑成型工艺优化[J].模具技术,2015(2):47-51.
[5] 严波,李阳,赵朋,等.基于改进有限体积法的三维注塑成型充模过程数值模拟[J].机械工程学报,2015,51(10):17-24.
[6] CHEN S Y,DOOLEN G D.Lattice Boltzmann method for fluid flows[J].Annual Review of Fluid Mechanics,1998,30:329-364.
[7] AIDUN C K,CLAUSEN J R.Lattice-Boltzmann method for complex flows[J].Annual Review of Fluid Mechanics,2010,42(1):439-472.
[8] DENG L,LIANG J J,ZHANG Y,et al.Efficient numerical simulation of injection mold filling with the lattice Boltzmann method [J].Engineering Computations,2017,34(2):307-329.
[9] HE X Y,CHEN S Y,ZHANG R Y.A lattice Boltzmann scheme for incompressible multiphase flow and its application in simulation of Rayleigh-Taylor instability [J].Journal of Computational Physics,1999,152(2):642-663.