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Title: Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites. Topical Report

Abstract

This project aimed to integrate, optimize, and validate the fiber orientation and length distribution models previously developed and implemented in the Autodesk® Simulation Moldflow® Insight (ASMI) software package for injection-molded long-carbon-fiber (LCF) thermoplastic composite structures. The project was organized into two phases. Phase 1 demonstrated the ability of the advanced ASMI package to predict fiber orientation and length distributions in LCF/polypropylene (PP) and LCF/polyamide-6, 6 (PA66) plaques within 15% of experimental results. Phase 2 validated the advanced ASMI package by predicting fiber orientation and length distributions within 15% of experimental results for a complex three-dimensional (3D) Toyota automotive part injection-molded from LCF/PP and LCF/PA66 materials. Work under Phase 2 also included estimate of weight savings and cost impacts for a vehicle system using ASMI and structural analyses of the complex part. The present report summarizes the completion of Phases 1 and 2 work activities and accomplishments achieved by the team comprising Pacific Northwest National Laboratory (PNNL); Purdue University (Purdue); Virginia Polytechnic Institute and State University (Virginia Tech); Autodesk, Inc. (Autodesk); PlastiComp, Inc. (PlastiComp); Toyota Research Institute North America (Toyota); Magna Exteriors and Interiors Corp. (Magna); and University of Illinois. Figure 1 illustrates the technical approach adopted in this project thatmore » progressed from compounding LCF/PP and LCF/PA66 materials, to process model improvement and implementation, to molding and modeling LCF/PP and LCF/PA66 plaques. The lessons learned from the plaque study and the successful validation of improved process models for fiber orientation and length distributions for these plaques enabled the project to go to Phase 2 to mold, model, and optimize the 3D complex part.« less

Authors:
 [1];  [1];  [2];  [2];  [3];  [3];  [4];  [4];  [4];  [5];  [6];  [6];  [7];  [8]
  1. Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
  2. Autodesk, Inc., Ithaca, NY (United States)
  3. Virginia Polytechnic Inst. and State Univ. (Virginia Tech), Blacksburg, VA (United States)
  4. Purdue Univ., West Lafayette, IN (United States)
  5. Toyota Research Inst. North America, Ann Arbor, MI (United States)
  6. PlastiComp, Inc., Winona, MN (United States)
  7. Magna Exteriors and Interiors Corporation, Aurora, ON (Canada)
  8. Univ. of Illinois, Urbana-Champaign, IL (United States)
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1399184
Report Number(s):
PNNL-25440
830403000
DOE Contract Number:
AC05-76RL01830
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; carbon fiber; long fiber thermoplastic; injection molding; process modeling; fiber orientation; fiber length; finite element; elastic properties; weight reduction

Citation Formats

Nguyen, Ba Nghiep, Fifield, Leonard S., Wang, Jin, Costa, Franco, Lambert, Gregory, Baird, Donald G., Sharma, Bhisham A., Kijewski, Seth A., Sangid, Michael D., Gandhi, Umesh N., Wollan, Eric J., Roland, Dale, Mori, Steven, and Tucker, III, Charles L. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites. Topical Report. United States: N. p., 2016. Web. doi:10.2172/1399184.
Nguyen, Ba Nghiep, Fifield, Leonard S., Wang, Jin, Costa, Franco, Lambert, Gregory, Baird, Donald G., Sharma, Bhisham A., Kijewski, Seth A., Sangid, Michael D., Gandhi, Umesh N., Wollan, Eric J., Roland, Dale, Mori, Steven, & Tucker, III, Charles L. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites. Topical Report. United States. doi:10.2172/1399184.
Nguyen, Ba Nghiep, Fifield, Leonard S., Wang, Jin, Costa, Franco, Lambert, Gregory, Baird, Donald G., Sharma, Bhisham A., Kijewski, Seth A., Sangid, Michael D., Gandhi, Umesh N., Wollan, Eric J., Roland, Dale, Mori, Steven, and Tucker, III, Charles L. Wed . "Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites. Topical Report". United States. doi:10.2172/1399184. https://www.osti.gov/servlets/purl/1399184.
@article{osti_1399184,
title = {Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites. Topical Report},
author = {Nguyen, Ba Nghiep and Fifield, Leonard S. and Wang, Jin and Costa, Franco and Lambert, Gregory and Baird, Donald G. and Sharma, Bhisham A. and Kijewski, Seth A. and Sangid, Michael D. and Gandhi, Umesh N. and Wollan, Eric J. and Roland, Dale and Mori, Steven and Tucker, III, Charles L.},
abstractNote = {This project aimed to integrate, optimize, and validate the fiber orientation and length distribution models previously developed and implemented in the Autodesk® Simulation Moldflow® Insight (ASMI) software package for injection-molded long-carbon-fiber (LCF) thermoplastic composite structures. The project was organized into two phases. Phase 1 demonstrated the ability of the advanced ASMI package to predict fiber orientation and length distributions in LCF/polypropylene (PP) and LCF/polyamide-6, 6 (PA66) plaques within 15% of experimental results. Phase 2 validated the advanced ASMI package by predicting fiber orientation and length distributions within 15% of experimental results for a complex three-dimensional (3D) Toyota automotive part injection-molded from LCF/PP and LCF/PA66 materials. Work under Phase 2 also included estimate of weight savings and cost impacts for a vehicle system using ASMI and structural analyses of the complex part. The present report summarizes the completion of Phases 1 and 2 work activities and accomplishments achieved by the team comprising Pacific Northwest National Laboratory (PNNL); Purdue University (Purdue); Virginia Polytechnic Institute and State University (Virginia Tech); Autodesk, Inc. (Autodesk); PlastiComp, Inc. (PlastiComp); Toyota Research Institute North America (Toyota); Magna Exteriors and Interiors Corp. (Magna); and University of Illinois. Figure 1 illustrates the technical approach adopted in this project that progressed from compounding LCF/PP and LCF/PA66 materials, to process model improvement and implementation, to molding and modeling LCF/PP and LCF/PA66 plaques. The lessons learned from the plaque study and the successful validation of improved process models for fiber orientation and length distributions for these plaques enabled the project to go to Phase 2 to mold, model, and optimize the 3D complex part.},
doi = {10.2172/1399184},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Jun 01 00:00:00 EDT 2016},
month = {Wed Jun 01 00:00:00 EDT 2016}
}

Technical Report:

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  • This quarterly report summarizes the status for the project planning to initiate all the legal and contract documents required for establishing the subcontracts needed and a Cooperative Research and Development Agreement (CRADA) with Autodesk, Inc., Toyota Motor Engineering and Manufacturing North America (Toyota), and Magna Exterior and Interiors Corporation (Magna). During the first quarter (10/1/2012 to 12/31/2012), the statements of work (SOW) for the subcontracts to Purdue University, University of Illinois, and PlastiComp, Inc. were completed. A draft of the CRADA SOW was sent to Autodesk, Toyota, and Magna for technical and legal reviews. PNNL Legal Services contacted project partners’more » Legal counterparts for preparing legal documents for the project. A non-disclosure agreement was drafted and sent to all the parties for reviews.« less
  • This quarterly report summarizes the status for the project planning to complete all the legal and contract documents required for establishing the subcontracts needed and a Cooperative Research and Development Agreement (CRADA) with Autodesk, Inc., Toyota Motor Engineering and Manufacturing North America (Toyota), and Magna Exterior and Interiors Corporation (Magna). During the second quarter (1/1/2013 to 3/31/2013), all the technical and legal documents for the subcontracts to Purdue University, University of Illinois, and PlastiComp, Inc. were completed. The revised CRADA documents were sent to DOE, Autodesk, Toyota, and Magna for technical and legal reviews. PNNL Legal Services contacted project partners’more » Legal counterparts for completing legal documents for the project. A non-disclosure agreement was revised and sent to all the parties for reviews.« less
  • This quarterly report summarizes the status for the project planning to obtain all the approvals required for a Cooperative Research and Development Agreement (CRADA) with Autodesk, Inc., Toyota Motor Engineering and Manufacturing North America (Toyota), and Magna Exterior and Interiors Corporation (Magna). The CRADA documents have been processed by PNNL Legal Services that is also coordinating the revision effort with the industrial parties to address DOE’s comments.
  • This quarterly report summarizes the status of the project planning to obtain all the approvals required for a Cooperative Research and Development Agreement (CRADA) with Autodesk, Inc., Toyota Motor Engineering and Manufacturing North America (Toyota), and Magna Exterior and Interiors Corporation (Magna). The final CRADA documents processed by PNNL’s Legal Services were submitted to all the parties for signatures.
  • The CRADA between PNNL, Autodesk, Toyota and Magna has been effective since October 28th, 2013. The whole team including CRADA and subcontract partners kicked off the project technically on November 1st, 2013. This report describes work performed during the first quarter of FY 2014. The following technical progresses have been made toward project milestones: 1) The project kickoff meeting was organized at PlastiComp, Inc. in Winona on November 13th, 2013 involving all the project partners. During this meeting the research plan and Gantt chart were discussed and refined. The coordination of the research activities among the partners was also discussedmore » to ensure that the deliverables and timeline will be met. 2) Autodesk delivered a research version of ASMI to PNNL for process modeling using this tool under the project. PNNL installed this research version on a PNNL computer and tested it. Currently, PNNL is using ASMI to prepare the models for PlastiComp plaques. 3) PlastiComp has compounded long carbon-fiber reinforced polypropylene and polyamide 6,6 compounds for rheological and thermal characterization tests by the Autodesk laboratories in Melbourne, Australia. 4) Initial mold flow analysis was carried out by PlastiComp to confirm that the 3D complex part selected by Toyota as a representative automotive part is moldable. 5) Toyota, Magna, PlastiComp and PNNL finalized the planning for molding the Toyota 3D complex part. 6) Purdue University worked with PNNL to update and specify the test matrix for characterization of fiber length/orientation. 7) Purdue University developed tools to automate the data collection and analysis of fiber length and orientation measurements. 8) Purdue University designed and specified equipment to replace the need for equipment using the technology established by the University of Leeds at General Motors.« less