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The present work focuses on the extensional rheometry test, performed with the Sentmanat extensional rheometer (SER) device, and its main objectives are: (i) to establish the modelling requirements, such as the geometry of the computational domain, initial and boundary conditions, appropriate case setup, and (ii) to investigate the effect of self-induced errors, namely on the sample dimensions and test temperature, on the extensional viscosity obtained through the extensional rheometry tests. The definition of the modelling setup also comprised the selection of the appropriate mesh refinement level to model the process and the conclusion that gravity can be neglected without affecting the numerical predictions. The subsequent study allowed us to conclude that the errors on the sample dimensions have similar effects, originating differences on the extensional viscosity proportional to the induced variations. On the other hand, errors of a similar order of magnitude on the test temperature promote a significant difference in the predicted extensional viscosity.

The practical application of a multi-objective optimization strategy based on evolutionary algorithms was proposed to optimize the plastics thermoforming process. For that purpose, in this work, differently from the other works proposed in the literature, the shaping step was considered individually with the aim of optimizing the thickness distribution of the final part originated from sheets characterized by different thickness profiles, such as constant thickness, spline thickness variation in one direction and concentric thickness variation in two directions, while maintaining the temperature constant. As far we know, this is the first work where such a type of approach is proposed. A multi-objective optimization strategy based on Evolutionary Algorithms was applied to the determination of the final part thickness distribution with the aim of demonstrating the validity of the methodology proposed. The results obtained considering three different theoretical initial sheet shapes indicate clearly that the methodology proposed is valid, as it provides solutions with physical meaning and with great potential to be applied in real practice. The different thickness profiles obtained for the optimal Pareto solutions show, in all cases, that that the different profiles along the front are related to the objectives considered. Also, there is a clear improvement in the successive generations of the evolutionary algorithm.

Rheology, defined as the science of the deformation and flow of matter, is a multidisciplinary scientific field, covering both fundamental and applied approaches [...]

In the present study, the simulation of the three-dimensional (3D) non-isothermal, non-Newtonian fluid flow of polymer melts is investigated. In particular, the filling stage of thermoplastic injection molding is numerically studied with a solver implemented in the open-source computational library O p e n F O A M ® . The numerical method is based on a compressible two-phase flow model, developed following a cell-centered unstructured finite volume discretization scheme, combined with a volume-of-fluid (VOF) technique for the interface capturing. Additionally, the Cross-WLF (Williams–Landel–Ferry) model is used to characterize the rheological behavior of the polymer melts, and the modified Tait equation is used as the equation of state. To verify the numerical implementation, the code predictions are first compared with analytical solutions, for a Newtonian fluid flowing through a cylindrical channel. Subsequently, the melt filling process of a non-Newtonian fluid (Cross-WLF) in a rectangular cavity with a cylindrical insert and in a tensile test specimen are studied. The predicted melt flow front interface and fields (pressure, velocity, and temperature) contours are found to be in good agreement with the reference solutions, obtained with the proprietary software M o l d e x 3 D ® . Additionally, the computational effort, measured by the elapsed wall-time of the simulations, is analyzed for both the open-source and proprietary software, and both are found to be similar for the same level of accuracy, when the parallelization capabilities of O p e n F O A M ® are employed.

Rheology, defined as the science of deformation and flow of matter, is a multidisciplinary scientific field, covering both fundamental and applied approaches [...]