An adaptive method to capture weldlines during the injection mold filling

Weldlines are generally unavoidable during the process of injection mold filling with even moderate complexity when two or more melts meet, which greatly influence the quality of the products. In this paper, we propose a new method to numerically simulate the mold filling process and to capture the weldline adaptively based on the Level Set/Ghost method. The cases where the weldlines are caused by two melt fronts in the injection mold filling process are analyzed, and our special interest is devoted to confirming the position and the shape of the weldline depending on the new adaptive technique based on the level set function. The numerical results show that the proposed method is feasible to detect the influence of the inset size, the inset shape and the inset center place on the weldline.