基于Giesekus黏弹性本构的注射成型数值算法研究

针对熔体的黏弹性特征,考虑熔体流动过程中的惯性作用,基于Giesekus模型建立了注射成型中熔体流动的黏弹性理论模型。将黏弹性本构方程整合为含瞬态项、对流项和源项的偏微分方程,基于有限体积法离散,提出了黏弹性本构方程的离散方法。借鉴有限元框架下的黏弹性离散分裂算法（DEVSS）,发展了以有限体积法为基础的黏弹性离散分裂算法（FVM-DEVSS）,开发了三维黏弹性流动的计算程序。用经典充分发展的4∶1收缩流验证方法的有效性,再结合充模流动实验,正确预测了熔体流动前沿、浇口压力及熔接线位置,通过光弹实验结果再次证明了本文方法的有效性。结果表明,本研究所发展的黏弹性算法可以有效表达熔体的黏性和弹性对流动压力的影响,而且能准确预测两股熔体相遇时熔接线的位置及形成过程。此外,本文黏弹性算法有效准确地计算了熔体充模过程中的流动诱导应力。     

聚合物熔体矩形流道挤出胀大的数值模拟

运用Picard迭代格式的有限元方法,采用Wagner积分型本构方程对黏弹流体挤出胀大进行三维模拟分析。每次迭代根据新的自由面边界位置重新划分网格,由前一次迭代得到的速度场,算出单元高斯点流线,沿流线积分计算应力,把应力作为拟体力,建立非线性方程组迭代格式。对不同宽度和长度的矩形流道的挤出胀大进行模拟计算,分析了流道宽度和长度对胀大率的影响,结果表明,随着宽厚比的增加,厚度胀大率随之增加,随着流道长度的增加,胀大率逐渐下降。并把结果与二维狭缝流道的数值模拟和实验结果相比较, 结果表明,用该方法对黏弹流体挤出胀大流动进行三维模拟是可行的和准确的。     

注塑模充填过程动态模拟

本文基于注塑模型腔内充填机理和流体力学基本方程，视聚合物熔体在型腔中的流动为平行板中的流动，在浇注系统中的流动为等效圆柱管内的流动，在此假定的基础上进行合理简化，建立了三维薄壁型腔的基于非弹性、非牛顿流体在非等温下的Ｈｅｌｅ－Ｓｈａｗ流动的数学模型及浇注系统的数学模型，并采用混合有限元／有限差分数值方法耦合求解压力方程和能量方程，采用控制体积法自动跟踪熔体前峰面，从而实现充填过程的动态模拟。模拟结     

低密度聚乙烯熔体毛细管挤出的数值模拟

借助2种微分型黏弹性本构模型DCPP模型和S-MDCPP模型来描述支化高分子熔体的复杂流变行为,并采用离散的弹性黏性应力分裂方法(DEVSS)/迎风流线方法(SU)解决黏弹性流体流动过程中的对流占优问题以及缺少椭圆算子的问题,进而用基于有限增量微积分(FIC)方法的压力稳定型分步算法求解质量守恒方程、动量守恒方程,对低...     

注塑成型充填过程的可压缩流动分析

注塑成型过程中,熔体在型腔中的流动和传热对制品质量性能有重要的影响.为了预测注塑制品的收缩、翘曲和力学性能,精确预测充填过程的流动及传热历史是十分必要的.本文考虑熔体的可压缩性及相变的影响,将充填过程中熔体的流动视为非牛顿可压流体在非等温状态下的广义Hele-Shaw流动.采用有限元/有限差分混合方法求解压力场和温度场,采用控制体积法跟踪熔体流动前沿,并应用Visual C++实现了注塑充填过程的可压缩流动分析.为了保证能量方程各项在单元内边界的连续性,结点能量方程各项由单元形心处的离散值加权平均获得,因而,能量方程在计算区域内整体求解.对两个算例进行了分析,模拟结果与实验结果的对比,验证了本文数值算法及程序.     

内层熔体预填量对溢流法水辅共注填充过程的影响

基于流体运动基本控制方程和Giesekus黏弹模型,在OpenFOAM流体计算开源平台上采用有限体积法编制了新求解器,同时采用体积分数法追踪多相流中的自由界面,并利用此求解器对溢流法水辅共注填充过程进行了仿真计算。系统地分析了内层熔体预填量对制品最终形态的影响,发现随着内层熔体预填量的增加,制件中空率减小,内层熔体的残余壁厚增加,皮层熔体则变化不明显;另外,基于熔体黏弹特质对结果进行了解释。还系统地进行了相关水辅共注实验,结果表明,其得到的结论和数值模拟所得结论相同。     

单螺杆挤出过程熔体输送段数值模拟方法

综述了应用于螺杆挤出成型过程熔体输送段数值模拟的各种计算方法，根据挤出过程聚合物流场控制方程，介绍了几种有代表性的聚合物本构关系，包括线性黏弹性和非线性黏弹性本构方程。概述了有限差分法、有限元法、有限体积法和边界元法等数值计算方法的特点和应用范围，并针对聚合物熔体流动模拟中的迭代收敛性和稳定性、耦合和解耦合、高Weissenberg数等问题进行了讨论，指出应该根据研究目的和实际情况选择适宜的本构方程和数值方法。     

子午线轮胎固有频率和阻尼辨识的数值与实验研究

研究了一种轮胎固有频率和阻尼比辨识的数值-实验混合方法。数值分析采用非线性有限元方法对强非线性黏弹性轮胎进行模态分析,给出轮胎有阻尼固有频率和无阻尼固有频率的求解,利用模态分量法辨识出各阶模态下的阻尼比。仿真计算结果和实验结果的对比表明,给出的求解固有频率和阻尼比的方法是可靠的。     

凹槽模型中聚合物溶液微观渗流的有限体积方法

为了形成对粘弹性聚合物溶液在微观孔隙中流动行为的完整的数学描述,便于从理论上研究粘弹性流体的微观驱油效率,本文针对残余油的微观存在形式,使用了凹槽流道模型。并结合非线性上随体Maxwell本构方程,动量方程、连续性方程以及两种流道的边界条件,建立了完整的数学模型。采用有限体积法求解了由UCM本构方程、动量方程、连续性方程和流道的边界条件构成的非线性耦合方程组。为了解决流场计算中的一个关键问题,即不合理的压力场的检测,同时为了保证计算的准确度及对压力的物理特性模拟,本文对整个计算域采用交错网格,并且采用乘方格式对动量方程进行离散,从而得出控制方程组的离散方程式。本文选择交替方向隐式迭代法,并补以块修正技术以促进收敛,最后得到了粘弹性流体在收缩流道内流动时的速度场、流函数场。     

聚合物熔体全三维非等温数值模拟

采用基于交错网格的有限体积法(FVM)离散了4大方程,给出了能量方程的全三维离散格式。运用SIMPLE算法求解了矩形截面流道内熔体的速度场和压力场,通过耦合动量方程和能量方程,进而得到整个机头流道内温度的分布。计算中采用了Carreau流变模型,并给出了作为温度函数的流动指数n的解析表达式。模拟结果表明:在入口区,熔体从近壁面区域向流道的中心区域汇集,进入全展流区后,熔体的流场不再变化;熔体内温度分布较为复杂,影响因素众多。     

计算机模拟狭缝口模截面塑料熔体流动行为

采用有限元方法分析了狭缝口模截面内塑料熔体的流动状态，实现的过程是通过MATLAB编程．对比了矩形口模和改进口模在速度分布的差异和对流率的影响，并将计算分析结果直观地以图形、图像显示出来。     

LDPE熔体在双螺杆挤出机中流动的有限元分析

利用大型有限元分析软件包ANSYS分析了低密度聚乙烯(LDPE)在双螺杆挤出机三头常规螺纹元件中的流动情况,讨论了整个流道的速度分布、压力分布、粘度分布及螺杆挤出特性曲线。计算结果表明：LDPE熔体在双螺杆挤出机中得到了充分的混合。     

A finite piece method for simulating polymer melt flows in extrusion sheet dies

A finite piece method is proposed to simulate three‐dimensional slit flows in extrusion sheet dies in this paper. The simulations concern incompressible fluids obeying different constitutive equations: generalized Newtonian (Carreau‐Yasuda law), and viscoelastic Phan‐Thien Tanner (PTT) models. Numerical simulations are carried out for the isothermal and nonisothermal flows of polymer melt through sheet dies. The Picard iteration method is utilized to solve nonlinear equations. The results of the finite piece method are compared with the three‐dimensional (3D) finite element method (FEM) simulation and experiments. At the die exit, the relative error of the volumetric flow between the finite piece method and the 3D FEM is below 1.2%. The discrepancy of the pressure distributions does not exceed 6%. The Maximum error of the uniformity index between the simulations and experiments is about 2.3%. It shows that the solution accuracy of the finite piece method is excellent, and a substantial amount of computing time and memory requirement can be saved. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

几种有限元分析方法在机头流道分析中的应用研究

研究了 3种有限元分析方法———流函数法、侧壁因子修正法和全高三棱柱单元法在挤出机平板机头流道分析中的应用情况。结果表明 ,流函数法只适合分析流道高度不变化或变化极小的情况 ;侧壁因子修正法误差较小 ;全高三棱柱单元法比较精确 ,但分析方法复杂     

塑料异型材挤出口模的三维罚有限元设计

讨论了现有塑料异型材挤出口模研究中的流变学分析方法,指出了前人运用流变学方法设计挤出口模的不足。本文采用三维罚有限元方法,对幂律流体在塑料异型材口模中的流动进行了计算机模拟研究,阐述了采用三维罚有限元方法进行塑料异型材挤出口模设计的重要意义     

Theoretical Analysis on Flow of Polymer Melts in Screw Die

Abstract

Flow of polymer melt in screw dies is theoretically analyzed by the broken section method with the uniformity of the extrudates. An isothermal, laminar and steady state power law fluid is assumed. The analysis is discussed in two parts, i.e., screw flow and die slit flow. A way of computer calculation by means of a method of iteration is presented by considering volume balance between screw flow and slit flow.

An ideal screw die is one in which pressure distribution is constant along the screw axis, i.e., the shape of the die slit is constant along the axis and the screw is such that the depth of screw channel decreases almost linearly.     

振动力场作用下聚合物熔体单螺杆挤出过程数值模拟

根据塑料电磁动态塑化挤出过程中熔体输送的实际情况，对三维模型进行简化，利用大型有限元软件ANSYS模拟了叠加轴向振动力场作用下聚合物熔体在螺槽中的流动情况，求解出周期性变化的速度，压力场分布，结果表明，与稳态挤出过程相比，振动力场的引入在进出口压力差恒定的情况下，可以提高熔全输送流率。采用有限元模拟方法可以为确定和优化工艺参数，产品质量控制提供指导。     

An in‐process ultrasonic approach to investigating the relaxation of orientation and disorientation of polymer melts

The orientation and relaxation behaviors of a low‐density polyethylene melt and polypropylene melts with different melt indices undergoing a shear flow in a restricted channel were investigated by using ultrasound. A capillary rheometer was used to force the polymer melt through a slit die equipped with pressure, temperature, and ultrasound sensors, and the variation of ultrasound velocity traversing the melt was measured. Experimental results revealed that due to different mechanisms involved, the relaxations of orientation and disorientation processes show different dependences of ultrasound velocity on shear rate, temperature, and melt index. POLYM. ENG. SCI., 2008. Published 2008 Society of Plastics Engineers     

Finite element modeling of the flow of a rubber compound through an axisymmetric die using the CEF viscoelastic constitutive equation

This work is devoted to the simulation of the flow of a high viscosity NR/SBR rubber compound through the die of a single screw extruder with axisymmetric geometry. An in-house developed computer code based on the use of continuous penalty finite element method was employed. Three constitutive equations including two generalized Newtonian models namely; power-law and Carreau and an explicit viscoelastic model named CEF (Criminale-Ericksen-Fillbey) were used to reflect the rheological behavior of the material. Using the parameters of the rheological models determined by a slit die rheometry technique, the flow of the compound was simulated through the die and results were compared with experimentally measured mass flow rates. It is shown that for high viscosity rubber compounds the use of generalized Newtonian models which do not take the normal stress in simple shear flow into consideration gives rise to significant errors in prediction of mass flow rates. On the other hand, comparing the simulations results using the CEF equation with experimental data revealed that this model is the best compromise between generalized Newtonian and full viscoelastic models which need high computational costs and effort. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Simulation of planar welding flows: Part 2. Strain history,stress calculation,and experimental comparison

A numerical method is described for calculating the stress a viscoelastic melt exhibits in a flow, based on approximate kinematics. The method assumes that the kinematics are reasonably close to those of a shear-thinning fluid such as the Carreau model. The strain history of a given flow and the resulting stress are calculated via a tracking method from finite element kinematics. Fullfield flow birefringence experiments were done for lowdensity polyethylene and polystyrene flowing past a thin plate divider in a 1.254-mm planar slit die. By digitally analyzing birefringence photographs of the flow field, the birefringence was measured over two dimensions. These birefringence results are in good agreement with birefringence fields calculated from the numerical simulations and the stress-optical law. The flow fields were most highly oriented in a region surrounding the weld interface just downstream of the plate divider. This orientation relaxed farther downstream, with polystyrene relaxing faster than low-density polyethylene.