Numerical simulation of “sand-like” polymer flow during rotational moulding using smoothed particle hydrodynamics method

Rotational moulding is a versatile polymer shaping process used to create enclosed parts from powdered precursors using heat and multi-axis rotation. Controlling the heating process and mould motion is critical to producing high-quality parts, and failures due to incorrect mould coverage or variable wall thickness are common. To date, limited simulation tools exist to predict the motion of the powder within the mould, and operators rely on unreliable prior experience to avoid defects. This paper presents an SPH simulation framework to predict particle flow patterns and powder contact time within a rotating mould. The powder-to-wall contact time was derived from the transient rigid body force (RBF) of different sensors on the mould. The method was compared with the results of DEM simulation and validated by the particle flow pattern of two experimental results. Results showed that the SPH method was capable of simulating particle flow macroscopic properties. The great computing efficiency of SPH compared to DEM simulation was also demonstrated.