The practical application of a multi-objective optimization strategy based on evolutionary algorithms was proposed to optimize the plastics thermoforming process. For that purpose, in this work, differently from the other works proposed in the literature, the shaping step was considered individually with the aim of optimizing the thickness distribution of the final part originated from sheets characterized by different thickness profiles, such as constant thickness, spline thickness variation in one direction and concentric thickness variation in two directions, while maintaining the temperature constant. As far we know, this is the first work where such a type of approach is proposed. A multi-objective optimization strategy based on Evolutionary Algorithms was applied to the determination of the final part thickness distribution with the aim of demonstrating the validity of the methodology proposed. The results obtained considering three different theoretical initial sheet shapes indicate clearly that the methodology proposed is valid, as it provides solutions with physical meaning and with great potential to be applied in real practice. The different thickness profiles obtained for the optimal Pareto solutions show, in all cases, that that the different profiles along the front are related to the objectives considered. Also, there is a clear improvement in the successive generations of the evolutionary algorithm.

The purpose of this paper is to develop new boundary conditions for simulating the injection molding process of polymer melts. The boundary conditions are derived and implemented to simulate real-life air vents (used to allow the air escape from the mold). The simulations are performed in the computational library OpenFOAM® by considering two different fluid models, namely, Newtonian and generalized Newtonian (Bird–Carreau model). A detailed study on the accuracy of the solver interFoam for simulating the filling stage is presented, by considering simple geometries and adaptive mesh refinement. The verified code is then used to study the three-dimensional filling of a more complex geometry. The results obtained showed that the numerical method is stable and allows one to model the filling process, simulating the real injection molding process.

This work presents numerical investigations for turbulent flow and heat transfer in a backward-facing step with and without porous inserts. Two classes of the model were employed, namely linear and nonlinear turbulence closures. The entire set of transport equations was discretized by means of the control volume method and the system of algebraic equations obtained was relaxed using the SIMPLE (Semi Implicit Pressure-Linked Equations) method. Results were first validated against the experimental data and the simulations follow experimental values and trends. Computations further indicated that when using the porous insert, the size, shape, and length of the recirculating region were drastically reduced in addition to being pushed toward the channel exit, leading eventually to a complete bubble suppression for thicker inserts. A more permeable medium gave better results in quickly suppressing the circulatory motions. By including porous inserts in the channel, turbulence generated due to the shear inside the recirculating region was damped, whereas high levels of k were concentrated within the permeable structure. Large variations for the skin friction factor along the bottom wall were also smoothed out by placing inserts, spanning from a typical distribution for an unobstructed back-step flow to a standard parallel channel flow distribution as the inserts got ticker. On the other hand, at the upper wall, flow pushed toward the top surface gave rise to a sudden increase of the skin friction factor, which was later stabilized downstream the flow. Heat transfer analysis followed showing damping for Nu at the bottom wall as the thickness of the porous substrate was increased. Overall, the thickness of the insert played a dominant role in changing the final flow and heat transfer characteristics rather than the porosity or permeability of the porous material. Finally, this work indicated that the sudden increase of Nu around the reattachment point, known to be undesirable in many practical situations for causing additional thermomechanical loads on the surface, may by avoided by the use of a porous obstacle past the back-step.