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

Abstract

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 lightweightmore » targets in the automotive industry.« less

Authors:
 [1];  [1];  [2];  [3];  [4];  [4];  [5]
  1. Toyota Research Inst. North America, Ann Arbor, MI (United States)
  2. Toyota Motor Corporation, Toyota (Japan). Material Creation & Analysis Dept.
  3. Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering
  4. Moldex3d Northern America Inc., Farmington Hills, MI (United States)
  5. Univ. of Wisconsin, Madison, WI (United States). Polymer Engineering Center
Publication Date:
Research Org.:
Univ. of Tennessee, Knoxville, TN (United States); Toyota Research Inst. North America, Ann Arbor, MI (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1491304
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Journal of Composites Science
Additional Journal Information:
Journal Volume: 2; Journal Issue: 2; Journal ID: ISSN 2504-477X
Publisher:
MDPI
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; compression molding; sheet material; computer-aided engineering (CAE); draping; recycled carbon fibers

Citation Formats

Song, Yuyang, Gandhi, Umesh, Sekito, Takeshi, Vaidya, Uday, Hsu, Jim, Yang, Anthony, and Osswald, Tim. A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials. United States: N. p., 2018. Web. doi:10.3390/jcs2020033.
Song, Yuyang, Gandhi, Umesh, Sekito, Takeshi, Vaidya, Uday, Hsu, Jim, Yang, Anthony, & Osswald, Tim. A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials. United States. doi:10.3390/jcs2020033.
Song, Yuyang, Gandhi, Umesh, Sekito, Takeshi, Vaidya, Uday, Hsu, Jim, Yang, Anthony, and Osswald, Tim. Fri . "A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials". United States. doi:10.3390/jcs2020033. https://www.osti.gov/servlets/purl/1491304.
@article{osti_1491304,
title = {A Novel CAE Method for Compression Molding Simulation of Carbon Fiber-Reinforced Thermoplastic Composite Sheet Materials},
author = {Song, Yuyang and Gandhi, Umesh and Sekito, Takeshi and Vaidya, Uday and Hsu, Jim and Yang, Anthony and Osswald, Tim},
abstractNote = {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.},
doi = {10.3390/jcs2020033},
journal = {Journal of Composites Science},
number = 2,
volume = 2,
place = {United States},
year = {2018},
month = {6}
}

Journal Article:
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