A new three-dimensional mixed finite element for direct numerical simulation of compressible viscoelastic flows with moving free surfaces

A Mixed Finite Element (MFE) method for 3D non-steady flow of a viscoelastic compressible fluid is presented. It was used to compute polymer injection flows in a complex mold cavity, which involves moving free surfaces. The flow equations were derived from the Navier-Stokes incompressible equations, and we extended a mixed finite element method for incompressible viscous flow to account for compressibility (using the Tait model) and viscoelasticity (using a Pom-Pom like model). The flow solver uses tetrahedral elements and a mixed velocity/pressure/extra-stress/density formulation, where elastic terms are solved by decoupling our system and density variation is implicitly considered. A new DEVSS-like method is also introduced naturally from the MINI-element formulation. This method has the great advantage of a low memory requirement. At each time slab, once the velocity has been calculated, all evolution equations (free surface and material evolution) are solved by a space-time finite element method. This method is a generalization of the discontinuous Galerkin method, that shows a strong robustness with respect to both re-entrant corners and flow front singularities. Validation tests of the viscoelastic and free surface models implementation are shown, using literature benchmark examples. Results obtained in industrial 3D geometries underline the robustness and the efficiency of the proposed methods.