Layered tetrahedral meshing of thin-walled solids for plastic injection molding FEM

This paper describes a method for creating a well-shaped, layered tetrahedral mesh of a thin-walled solid by adapting the surface triangle sizes to the estimated wall thickness. The primary target application of the method is the finite element analysis of plastic injection molding, in which a layered mesh improves the accuracy of the solution. The edge lengths of the surface triangles must be proportional to the thickness of the domain to create well-shaped tetrahedrons; when the edge lengths are too short or too long, the shape of the tetrahedron tends to become thin or flat. The proposed method creates such a layered tetrahedral mesh in three steps: (1) create a preliminary tetrahedral mesh of the target geometric domain and estimate thickness distribution over the domain; (2) create a non-uniform surface triangular mesh with edge length adapted to the estimated thickness, then create a single-layer tetrahedral mesh using the surface triangular mesh; and (3) subdivide tetrahedrons of the single-layer mesh into multiple layers by applying a subdivision template. The effectiveness of the layered tetrahedral mesh is verified by running some experimental finite element analyses of plastic injection molding.