Modeling of the thermal contact resistance time evolution at polymer–mold interface during injection molding: Effect of polymers' solidification

• The validity of a solid–liquid thermal contact resistance model is evaluated in injection molding process.
• Crystallization is well taken into account in the predictions.
• Good agreement was found between the thermal contact resistance model and the experimental results.

The prediction of the thermal contact resistance (TCR) evolution at polymer–mold interfaces in injection process is a key point and presents a great challenge to thermal engineers for fast simulation of the composite molding processes. In the recent studies, TCR models for rough solids contact have been modified and improved to better predict the TCR at solid–liquid interface in steady state condition varying the applied pressure or in transient condition with constant applied pressure. This study deals with the applicability of one of the existing models to predict the TCR at polymers and molds interfaces in injection process when the temperature and the pressure vary simultaneously. The model was found to be able to predict reliably the TCR even during the crystallization of the polymer at the contact interface. In addition, it has been compared with earlier experimental measurements obtained on several mold surface roughness orders, and mold surface materials. It was found to match well these earlier experimental unpublished results.

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