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We describe a simulation of compression mold filling that combines a Galerkin finite element solution of the governing equations with a control volume scheme for tracking the moving flow front. The method can model thin shell-like parts in three dimensions, single or multiple charges, and multiply-connected domains. Either the generalized Hele-Shaw formulation or the thin-charge limit of Barone and Caulk's model can be used for the governing equations. The numerical techniques are explained, with special attention to the recovery of approximate flow front shapes. Predictions compare favorably to experiments, including laboratory experiments on model fluids as well as two large commercial parts molded from sheet molding compound. The simulation is most accurate when the initial charge thickness in uniform, but can also model multi-thickness charges.

Compression Mold Filling Simulation for Non-Planar Parts