pps proceeding - Abstract Preview
pps proceeding
Symposium: S03 - Injection Molding and Micromolding
Oral Presentation
 
 

Improving Fiber Orientation Predictions for Injection Molded Thermoplastics

Boyce Kennedy (1)*, Baird Donald (1)

(1) Virginia Tech - Virginia - USA

This work aims to further the understanding of the relationship between flow properties, orientation, and related mechanical properties of injection molded parts. The flow properties of a fiber reinforced polymer composite during molding directly relate to the stiffness and the strength of the completed part. Injection molding is a combination of shear and extensional flows which affect the orientation of the fibers within the polymer matrix and vary at locations within the mold cavity. Mechanical properties of fiber reinforced polymer parts, such as stiffness and strength, are dependent on the average length of the fibers and their oriented. The ability to predict, and ultimately control, flow properties allows for the ability to more efficiently design safe parts for industrial uses, such as vehicle parts in the automotive industry. A lab developed simulation packaged has been designed to predict the orientation and, therefore, modulus of long glass fiber reinforced polypropylene composites by accounting for the fibers’ flexibility. With the improved simulation package, the flexible fiber model was proven to be more accurate for predicting fiber orientation than traditional rigid fiber models when tested using long glass fiber reinforced polypropylene. The goal of this work is to test the universality of the existing model using long carbon fiber reinforced nylon 6,6 composites by injection molding parts and performing experiments to check their tensile strength and modulus. The methodology for collecting the data and the ability of the simulation to converge has been proven for the new material. The universality of the simulation package will be further determined by comparing the accuracy of the results for the two materials in a full three-dimensional simulation.