Mathematical modelling and experimental investigation of the flow molten plastic in injection molding

m MATHEMATICAL MODELLING AND EXPERIMENTAL INVESTIGATION OF TIIE FLOW OF MOLTEN PLASTIC IN INJECTION MOLDING (PhD Thesis) Abdulmecit GÜLDAŞ GAZİ UNIVERSITY INSTITUTE OF SCIENCE AND TECHNOLOGY July 2004 ABSTRACT In this work accomplished, Navier-Stokes equations were used for analyzing the flow of molten plastic in the mold cavity. Differential equations were discretised using Finite Control Volume method. In discretisation process, Full Implicit and Upwind methods were used. Furthermore, SIMPLE algorithm was used for calculating pressure. In the study, for determining of rheological properties of HDPE material that was used for flow analyzing, an experimental study was performed using an apparatus of melt flow index. To compare the simulation images obtained theoretically with real flow, a mold that a glass plate was mounted on a side of which was designed and manufactured. Real flow of molten plastic in the cavity was monitored by digital video camera. In addition, filling analysis of the same mold cavity was performed by Moldflow package. Flow simulations obtained from numerical analysis were compared with real flow behaviors obtained from experimental study and results of the filling simulation analysis of the software were compatible each others.IV Science Code : 626.12.00 Key Words : Injection molding, Flow simulation, Mathematical modelling, Navier Stokes equations, Finite Control Volume, Numerical analysis, Melt Flow Index, Viscosity, Flow Behavior (Power law) Index Page Number : 266 Adviser : Assoc. Prof. Ahmet ÖZDEMİR