ADMOS 2025

Mesh Adaptation for Two-Phase Flow Simulations in Polymer Injection Molding

  • Ferrer Fabón, Blanca (RWTH Aachen University)
  • Behr, Marek (RWTH Aachen University)

Please login to view abstract download link

In the field of polymer injection molding, the accuracy of numerical simulations is crucial to minimize manufacturing defects. The accurate simulation of such a complex process is computationally expensive and can greatly benefit from advanced adapting meshing techniques. In this study, we present a macro-scale two-phase flow formulation for polymer injection molding. We use an in-house finite-element solver to simulate the polymer and air flows as an interfacial flow, utilizing the level-set method. In these two-phase flow simulations, where the interface constitutes only a small part of the entire domain, adaptive mesh refinement can significantly improve the simulation’s efficiency. In our work, we explore localized refinement in time, achievable through a time-discontinuous space-time discretization [1]. This methodology can noticeably reduce the computational time while ensuring a high-fidelity resolution around the moving polymer-air interface. We will present our findings on the application of this adaptive meshing technique to a realistic injection molding test case and discuss how adaptive time refinement can lead to improved accuracy and performance in interfacial flow simulations. [1] von Danwitz M, Voulis I, Hosters N, Behr M. Time-continuous and time-discontinuous space-time finite elements for advection-diffusion problems. Int J Numer Methods Eng. 2023; 124(14): 3117-3144. doi:10.1002/nme.7241