A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials

Song, Yuyang; Gandhi, Umesh; Sekito, Takeshi; Vaidya, Uday; Hsu, Jim; Yang, Anthony; Osswald, Tim

doi:10.3390/jcs2020033

A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials

Journal Article · Fri Jun 01 00:00:00 EDT 2018 · Journal of Composites Science

DOI:https://doi.org/10.3390/jcs2020033· OSTI ID:1491304

Song, Yuyang ^[1]; Gandhi, Umesh ^[1]; Sekito, Takeshi ^[2]; Vaidya, Uday ^[3]; Hsu, Jim ^[4]; Yang, Anthony ^[4]; Osswald, Tim ^[5]

Toyota Research Inst. North America, Ann Arbor, MI (United States)
Toyota Motor Corporation, Toyota (Japan). Material Creation & Analysis Dept.
Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering
Moldex3d Northern America Inc., Farmington Hills, MI (United States)
Univ. of Wisconsin, Madison, WI (United States). Polymer Engineering Center

Its high-specific strength and stiffness with lower cost make discontinuous fiber-reinforced thermoplastic (FRT) materials an ideal choice for lightweight applications in the automotive industry. Compression molding is one of the preferred manufacturing processes for such materials as it offers the opportunity to maintain a longer fiber length and higher volume production. In the past, we have demonstrated that compression molding of FRT in bulk form can be simulated by treating melt flow as a continuum using the conservation of mass and momentum equations. However, the compression molding of such materials in sheet form using a similar approach does not work well. The assumption of melt flow as a continuum does not hold for such deformation processes. To address this challenge, we have developed a novel simulation approach. First, the draping of the sheet was simulated as a structural deformation using the explicit finite element approach. Next, the draped shape was compressed using fluid mechanics equations. The proposed method was verified by building a physical part and comparing the predicted fiber orientation and warpage measurements performed on the physical parts. The developed method and tools are expected to help in expediting the development of FRT parts, which will help achieve lightweight targets in the automotive industry.

View Accepted Manuscript (DOE)

Research Organization:: Univ. of Tennessee, Knoxville, TN (United States); Toyota Research Inst. North America, Ann Arbor, MI (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1491304

Journal Information:: Journal of Composites Science, Journal Name: Journal of Composites Science Journal Issue: 2 Vol. 2; ISSN 2504-477X

Publisher:: MDPICopyright Statement

Country of Publication:: United States

Language:: English

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Editorial for the Special Issue on Discontinuous Fiber Composites Osswald, Tim Journal of Composites Science, Vol. 2, Issue 4 https://doi.org/10.3390/jcs2040063	journal	October 2018

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Related Subjects

36 MATERIALS SCIENCE
compression molding
computer-aided engineering (CAE)
draping
recycled carbon fibers
sheet material

A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials

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References (15)

Cited By (1)

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