[Case study] Compression molding simulation with cross-rib geometry
- Module
- Compression Molding
Predicting the deformation behavior of fiber and resin during compression molding
Compression molding of discontinuous long-fiber reinforced plastic results in fiber deformation, localized orientation, and weld line generation. These characteristics affect the strength of the part, so they must be predicted accurately.
2D Randomly-Oriented Glass Fibers (ROF)
In this case study, the forming material is discontinuous long-fiber reinforced plastic called Randomly-Oriented Fibers (ROF).
- Material: Tepex® flowcore (Bond-Laminates GmbH)
- Glass fiber length: 30 - 50mm
- Fiber orientation: 2D Random orientation
- Fiber volume content (VF): 47%
- Matrix resin: Nylon 6 (Polyamide)
ROF type discontinuous long-fiber reinforced plastic: Actual material (left), Simulation model (right)
Compression molding simulation with cross-rib geometry
To evaluate the beam-in-solid coupling method, a compression molding test with a cross-rib geometry was performed. The comparison of deformation mid-way through the test and simulation shows good correlation.
Comparison between the mid-test deformation geometry (left) and the simulation result (right)
From the simulation result, fiber orientation can be evaluated by looking at the beam elements. It also shows a region at the base of the rib where there are less fibers (a matrix resin rich region). Similarly, by looking at the deformation geometry of solid elements, a weld line can be seen. The weld line at the tip of the rib is found in both the simulation and the test.
Deformed geometry of fiber (beam) and matrix resin (solid)
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