Using the reverse geometry method for warpage compensation on changing meshes with interpolation methods

Abstract In the manufacturing process of injection molding, the geometric accuracy of the produced part is affected by shrinkage and warpage. To support efforts to compensate for these effects, this paper presents an extension of the numerical compensation approach known as the reverse geometry method. The reverse geometry method is based on the numerical forward simulation of the displacement field resulting from shrinkage and warpage. It is an iterative method that performs node‐based compensation in each step. The mention of node‐based compensation already indicates that the method is associated with a computational mesh. In particular, in its basic version, it is linked to a specific mesh that must be kept identical during all iteration steps. This requirement is not always compatible with commercial simulation tools for injection molding, which enforce automatic remeshing between simulations. We present an interpolation method that allows to handle changing meshes and illustrate the method with two practical examples.