Stability analysis of injection molding flows

We numerically investigate the stability problem of the injection molding process. It was indicated by Bulters and Schepens Bulters and Schepens 2000 that surface defects of injection molded products may be attributed to a flow instability near the free surface during the filling stage of the mold. We examine the stability of this flow using the extended Pom–Pom constitutive equations. The model allows for controlling the degree of strain hardening of the fluids without affecting the shear behavior considerably. To study the linear stability characteristics of the injection molding process we use a transient finite element algorithm that is able to efficiently handle time dependent viscoelastic flow problems and includes a free surface description to take perturbations of the computational domain into account. It is shown that the fountain flow, which is a model flow for the injection molding process, is subject to a viscoelastic instability. If the various rheologies are compared, we observe that the onset of unstable flow can be delayed by increasing the degree of strain hardening of the fluid by increasing the number of arms in the Pom–Pom model . The most unstable disturbance which is obtained after exponential growth is a swirling flow near the fountain flow surface which is consistent with the experimental findings. © 2004 The Society of Rheology. DOI: 10.1122/1.1753276