Numerical simulation of the filling behavior of a Non‐Newtonian Fluid

Abstract A numerical model for free surface flows of non‐newtonian liquids which are injected into a cavity is presented. These flows are regarded as a basic model of injection molding. Model experiments of the injection process are performed with a water‐based gel. The flow equations are integrated according to the finite‐volume‐method. The volume of fluid method (VoF) is employed in order to describe the free surface flow of two incompressible phases, the phase interface is resolved by the method of geometric reconstruction. The Herschel‐Bulkley model is used in order to describe shear‐thinning behavior of the molding material and the effects of a yielding point. Different patterns of the filling flow depending on the injection parameters are evident in the experiment and the simulation. They are characterized and arranged with respect to the similarity parameters of the flow. Again, the results of the simulation are found to agree well with the experimental observations. (© 2006 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)