Three-dimensional simulation of the rubber injection molding process

Conventional shell element based simulation programs, usually referred to as 2(1)/(2)-dimensional, reach their limits for thick rubber parts as well as in critical molding areas like sudden wall thickness changes or at ribs. Three-dimensional programs for the simulation of the rubber injection molding process have been developed at IKV and in co-operation with industrial partners. These programs allow the three-dimensional, non-stationary, nonisothermal flow calculation for shear-thinning and incompressible rubber compounds during the filling stage and the calculation of the curing stage as well. Simulation and experiment show a good correspondence. By consideration of inertial forces, even the prediction of jetting is possible. In comparison to a 2(1)/(2)-dimensional simulation, the flow front progress is predicted more accurately.