pps proceeding - Abstract Preview
pps proceeding
Symposium: S03 - Rheology and Process Simulation
Oral Presentation
 
 

Modeling of Injection Overmolded Stamp Formed Thermoplastic Composites

Costa Franco S (1)*

(1) Autodesk - VIC - Australia

A method is developed to predict the final warp shaped of a hybrid forming and injection overmolding manufacturing process for thermoplastic composites. The model couples the output (residual stresses, anisotropic properties and thickness changes) of an existing stamp forming simulation software tool (Aniform) into the combined finite element warpage simulation of the injection overmolding process (Autodesk Moldflow). The residual stresses from the forming process together with the in-mold residual stresses and cooling strains of the injection overmolded compound are the drivers of warpage prediction in the combined part. A model of the interface bond strength between the stamp formed composite and the injection molding compound is also developed based on the temperature history at the bonding interface. Outcomes from the warp simulation and bond strength model are compared to experimental results on molded hybrid parts including a complex industrial part.