Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Second FY 2015 Quarterly Report
- Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
During the second quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Autodesk reviewed 3D fiber orientation distribution (FOD) comparisons and provided support on improving accuracy. 2) Autodesk reviewed fiber length distribution (FLD) data comparisons and provided suggestions, assisted PNNL in FOD and FLD parameter settings optimization, and advised PNNL on appropriate through thickness thermal conductivity for improved frozen layer effect on FOD predictions. Autodesk also participated in project review meetings including preparations and discussions towards passing the go/no-go decision point. 3) Autodesk implemented an improved FOD inlet profile specification method through the part thickness for 3D meshes and provided an updated ASMI research version to PNNL. 4) The University of Illinois (Prof. C.L. Tucker) provided Autodesk with ideas to improve fiber orientation modeling 5) Purdue University re-measured fiber orientation for the fast-fill 50wt% LCF/PA66 edge-gated plaque, and delivered the fiber orientation data for this plaque at the selected locations (named A, B, and C, Figure 1) to PNNL. Purdue also re-measured fiber orientation for locations A on the fast-fill 30wt% LCF/PP and 50wt% LCF/PA66 center-gated plaques, which exhibited anomalous fiber orientation behavior. 6) Purdue University conducted fiber length measurements and delivered the length data to PNNL for the purge materials (slow-fill 30wt% LCF/PP and 30wt% LCF/PA66 purge materials) and PlastiComp plaques selected on the go/no-go list for fiber length model validation (i.e., slow-fill edge-gated 30wt% LCF/PP and 30wt% LCF/PA66 plaques, Locations A, B, and C). 7) PNNL developed a method to recover intact carbon fibers from LCF/PA66 materials. Isolated fibers were shipped to Purdue for length distribution analysis. 8) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber orientation (FO) model validation and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 9) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber length distribution (FLD) model validation and compared the predicted length distributions with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 10) PNNL tested the new ASMI version received from Autodesk in March 2015, examined and discussed 3D fiber orientation predictions for PlastiComp plaques. 11) PlastiComp, Inc. (PlastiComp), Toyota Research Institute North America (Toyota) and Magna Exteriors and Interiors Corporation (Magna) participated in discussions with team members on the go/no-go plan. Toyota continued the discussion with Magna on tool modification for molding the complex part in order to achieve the target fiber length in the part.
- Research Organization:
- Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- AC05-76RL01830
- OSTI ID:
- 1183627
- Report Number(s):
- PNNL-24259; 830403000
- Country of Publication:
- United States
- Language:
- English
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