The simulation of three-dimensional (3D) non-isothermal

non-Newtonian fluid filling process is an extremely difficult task and remains a challenging problem

which includes polymer melt flow with free surface coupled with transient heat transfer. This paper presents a full 3D non-isothermal two-phase flow model to predict the complex flowinmelt filling process

where the Cross-WLFmodel is applied to characterize the rheological behavior of polymer melt. The governing equations are solved using finite volume method with SIMPLEC algorithm on collocated grids and the melt front is accurately captured by a high resolution level set method. A domain extension technique is adopted to dealwith the complex cavities

which greatly reduces the computational burden. To verify the validity of the developed 3D approach

the melts filling processes in two thin rectangular cavities (one of them with a cylindrical insert) are simulated. The predicted melt front interfaces are in good agreement with the experiment and commercial software prediction. For a case with a rather complex cavity

the dynamic filling process in a hemispherical shell is successfully simulated. All of the numerical results show that the developed numerical procedure can provide a reasonable prediction for injection molding process.