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A numerical formulation is presented for simulating the injection-molding filling of thin cavities, together with the delivery system, in three dimensions. The modelling is based on generalized Hele-Shaw flow for an inelastic, non-Newtonian fluid under non-isothermal conditions, which has been previously shown to be satisfactory for simulating the polymer melt flow in the cavities. A hybrid numerical scheme is employed in which the injection-molded part is described by two-dimensional triangular elements, provided that the cavity thickness is relatively thin, and the gapwise and time derivatives are expressed in terms of finite differences. The elements are flat, but can have any orientation in 3-D space to approximate the surfaces of the molded part.

Dynamic Simulation and Graphics for the Injection Molding of Three-Dimensional Thin Parts