Theoretical and experimental comparison of mesh types used in CAE injection molding simulation software

Moldflow Plastics Insight 4.1 currently uses four different types of mesh to represent the geometry of a plastic part for analysis. These four mesh types are beam elements (1D), midplane elements (2.5D), Dual Domain™ elements (modified 2.5D) and three dimensional (3D) elements. Each type of mesh has its own advantages and limitations. The purpose of this study was to evaluate the melt front advancement simulation results for various part geometries using each different meshing technique. Numerical simulation results are compared to actual experimental moldings of a flying disk shaped part and a hair comb. The mold filling behavior observed with the disc mold was accurately predicted by all mesh types. The filling pattern results of the comb analyses however varied greatly depending on the mesh type used and the model thickness interpretation. It is intended that users of CAE injection molding software tools can use the research presented in this paper as a guide to selecting and using the correct mesh type for a filling analysis on their particular part geometry.