Simulation of dispersed phase evolution for immiscible polymer blends in injection molding

Abstract

Purpose The numerical simulation of dispersed-phase evolution in injection molding process of polymer blends is of great significance in both adjusting material microstructure and improving performances of the final products. This paper aims to present a numerical strategy for the simulation of dispersed-phase evolution for immiscible polymer blends in injection molding. Design/methodology/approach First, the dispersed-phase modeling is discussed in detail. Then the Maffettone–Minale model, affine deformation model, breakup model and coalescence statistical model are chosen for the dispersed-phase evolution. A general coupled model of microscopic morphological evolution and macroscopic flow field is constructed. Besides, a stable finite element simulation strategy based on pressure-stabilizing/Petrov–Galerkin/streamline-upwind/Petrov–Galerkin method is adopted for both scales. Findings Finally, the simulation results are compared and evaluated with the experimental data, suggesting the reliability of the presented numerical strategy. Originality/value The coupled modeling of dispersed-phase and complex flow field during injection molding and the tracing and simulation of droplet evolution during the whole process can be achieved.