With the development of the CAD/DAM, injection molding process is widely used for net shape manufacturing in recent days. Numerical analysis of injection molding usually consists of three major stages has the most significiant such as filling, cooling, and packing. among them, especially filling stage is a very important effect on the quality of products and the other states.
There are mainly two methods in numerical simulation of filling stage. One employs the control volume concept that uses FAN(flow analysis network) method, and the other is the moving boundary method which needs remeshing in each time step. Although the control volume concept has a short computing time. It frequently results in relatively inaccurate pressure distribution or improper melt front advancement. However the moving boundary method yields good numerical results. It is in the case of Lagrangian method difficult to apply boundary conditions to complex shapes.
In this thesis, pressure, velocity and temperature profile were obtained by assuming the generalized Hele Shaw flow and adopting the velocity reflection method at wall boundaries. Especially, remeshing which was achieved by applying a spline curve shows good melt front lines. A newly proposed solution method to determine flow field of the melt front at the boundary decreases computing time and gives good results.
Injection molding of circular plates, tensile specimens, bending speciments, and rotor blades were modelled by the proposed numerical simulation technique. The results showed pressure distribution, temperature profile, velocity vectors, and the melt front advancement which are acceptable compared with reported experimental and numerical result.
