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Title: Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Fourth FY 2015 Quarterly Report

During the last quarter of FY 2015, the following technical progress has been made toward project milestones: 1) PlastiComp used the PlastiComp direct in-line (D-LFT) Pushtrusion system to injection mold 40 30wt% LCF/PP parts with ribs, 40 30wt% LCF/PP parts without ribs, 10 30wt% LCF/PA66 parts with ribs, and 35 30wt% LCF/PA66 parts without ribs. In addition, purge materials from the injection molding nozzle were obtained for fiber length analysis, and molding parameters were sent to PNNL for process modeling. 2) Magna cut samples at four selected locations (named A, B, C and D) from the non-ribbed Magna-molded parts based on a plan discussed with PNNL and the team and shipped these samples to Virginia Tech for fiber orientation and length measurements. 3) Virginia Tech started fiber orientation and length measurements for the samples taken from the complex parts using Virginia Tech’s established procedure. 4) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, reviewed process datasheets and performed preliminary analyses of these complex parts using the actual molding parameters received from Magna and PlastiComp to compare predicted to experimental mold filling patterns. 5) Autodesk assisted PNNL in developing the workflow to use Moldflow fibermore » orientation and length results in ABAQUS® simulations. 6) Autodesk advised the team on the practicality and difficulty of material viscosity characterization from the D-LFT process. 7) PNNL developed a procedure to import fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS® model for structural analyses of the complex part for later weight reduction study. 8) In discussion with PNNL and Magna, Toyota developed mechanical test setups and built fixtures for three-point bending and torsion tests of the complex parts. 9) Toyota built a finite element model for the complex parts subjected to torsion loading. 10) PNNL built the 3D ABAQUS® model of the complex ribbed part subjected to 3-point bending. 11) University of Illinois (Prof. C.L. Tucker) advised the team on fiber orientation and fiber length measurement options, modeling issues as well as interpretation of data.« less
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Publication Date:
OSTI Identifier:
Report Number(s):
PNNL-24834 Rev. 1
DOE Contract Number:
Resource Type:
Technical Report
Research Org:
Pacific Northwest National Laboratory (PNNL), Richland, WA (US)
Sponsoring Org:
Country of Publication:
United States
Injection molding; long carbon fiber; thermoplastic, process modeling, fiber orientation, fiber length, structural analysis, bending, torsion