pps proceeding - Abstract Preview
pps proceeding
Symposium: S12 - Process modeling and simulations
Oral Presentation
 
 

Role of Flow-Type on the Fiber Orientation Prediction in Injection Molding

Chen Hongyu (1)*, Wapperom Peter (2), Baird Donald (1)

(1) Department of Chemical Engineering, Virginia Tech - VA - USA, (2) Department of Mathematics, Virginia Tech - VA - USA

Fiber reinforced thermoplastic composites attract tremendous interest in the transportation industry, because they meet the light-weighting requirement and maintain the ability to be injection molded into complex shapes. However, the injection molding process results in a complex orientation state throughout the final parts. The mechanical properties are highly dependent on the fiber orientation distribution. Therefore, it is important to accurately predict fiber orientation profile generated during processing for the improvement of mechanical properties of the as formed composites. Various fiber orientation models were developed with a strain reduction factor, which takes a value between zero and one to reflect the slower evolution of fiber orientation observed experimentally. During mold filling, the flow conditions, such as extensional, simple shear, rotational flow and mixed flows, have significant effects on fiber orientation kinematics. However, a constant value of the strain reduction factor is not able to reflect different fiber re-orientation speeds under different flow types. In this study, we propose a new way to reflect the flow-type dependent fiber evolution kinematics. Specifically, a dimensionless flow-type parameter is applied to identify the local flow type. A local strain reduction factor is then determined by a function of this flow-type parameter. This method is verified with the generation of an injection molded center-gated disk. The predictions are compared with the experimental data results and show improved agreement of the profile shape with the experimental data compared to the use of a constant strain reduction factor.