This work employs a coupled analysis of the fluid flow and heat transfer in the polymer melt during the filling and post-filling stages of the injection-molding process and of mold cooling/heating which occurs during the entire process. Polymer melt analysis (PMA) has been carried out through a unified theoretical model implemented using a hybrid finite-element/finite-difference/control-volume numerical solution of the generalized Hele-Shaw flow of a compressible viscous fluid under non-isothermal conditions. Further, mold-cooling analysis (MCA) has been carried out utilizing a periodic heat conduction model implemented using a modified three-dimensional boundary-element method. To faithfully accommodate the effects of mold cooling on the fluid flow and heat transfer in the polymer melt, PMA and MCA have been coupled for appropriate data exchange and iterations carried out until a convergent solution for mold temperatures and for flow, pressure and temperatures within the polymer melt is obtained. The results obtained from this integrated simulation for different test cases have been compared with experimental data and a favorable agreement has been noticed. Using an illustrative example, the results are discussed in detail.

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