An adaptive multiphase finite element framework for simulating two-dimensional rotational molding

Abstract Rotational molding, also known as rotomolding, is a widely used manufacturing process for composite tank liners. Developing this process to obtain high quality liners is usually a long and delicate step. The implementation of numerical simulation can facilitate and expedite its development. It is challenging to obtain information about polymer movement through experimental methods. In this paper, we present a two-dimensional thermo fluid simulation of rotomolding using the immersed boundary approach with the level set technique. Numerical simulation using the Eulerian approach with the finite element method with anisotropic mesh refinement and the immersed boundary method has proven to be a powerful tool for analyzing and optimizing the molding processes with the help of implicit boundary and adaptive anisotropic meshing techniques. The finite element method is a valuable tool that allows us to combine several physical elements. This approach enables us to identify critical process variables and optimize design choices. To verify our methodology, we first simulated a 2D cross section of the mold by incorporating a two phase flow problem involving the polymer/air interface.