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The non‐isothermal filling of a powder/binder mixture in metal injection moulding is simulated by the viscoplastic and the heat conduction finite element methods. Proposes a simplified three‐dimensional scheme for the moulding of products with a non‐uniform thickness distribution. The computing time for the simplified three‐dimensional scheme is of the same order as that for two‐dimensional problems. Deals with complex overlapping between the surfaces of the mixture, resulting from the occurrence of jetting during the moulding, by the use of a remeshing scheme. The material flow in metal injection moulding into a rectangular die with a linear thickness distribution is simulated. The jetting behaviour is remarkably influenced by the thickness distribution of the die.

A technique combining finite elements and boundary elements is promising for unbounded field problems. A hypothetical boundary is assumed in the unbounded domain, and the usual finite element method is applied to the inner region, while the boundary element method is applied to the outer infinite region. On the coupling boundary, therefore, both potential and flux must be compatible. In the finite element method, the flux is defined as the derivative of the potential for which a trial function is defined. In the boundary element method, on the other hand, the same polynomial function is chosen for the potential and the flux. Thus, the compatibility cannot be satisfied unless a special device is considered. In the present paper, several compatibility conditions are discussed concerning the total flux or energy flow continuity across the coupling boundary. Some numerical examples of Poisson and Helmholtz problems are demonstrated.