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Simulation of polyurethane foam expansion with finite pointset and volume of fluid methods: implementation and experimental validation

Abstract The numerical simulation of the polyurethane foam expansion involves highly coupled thermo-chemo-rheological phenomena. A theoretical model including chemical reactions and thermo-rheological coupling of conservation equations was developed. Based on this model, 3D numerical simulation was carried out on the mould filling of polyurethane foam, by using finite pointset method and volume of fluid method in order to predict flow field, flow front advancement, temperature and density distributions during mould filling. The overall modelling was validated by using short shot foams obtained with a panel mould cavity. Mould filling of an automotive underlay carpet cavity was investigated numerically. The validation of this model has been carried out by comparing the final front positions between numerical and experimental results. The present numerical modelling of the foaming process is very useful to analyse the moulding process at the early stage of the product development in order to shorten time-to-market cycles and to reduce the costs of prototypes.