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Title: Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2016 First Quarterly Report

During the first quarter of FY 2016, the following technical progress has been made toward project milestones: 1) Virginia Tech completed fiber orientation (FO) measurements for the samples taken at Locations A, B, C and D (Figure 1) from the 30wt% LCF/PP and 30wt% LCF/PA66 ribbed and non-ribbed complex parts using Virginia Tech’s established procedure. Virginia Tech delivered to PNNL all the measured fiber orientation data for validating ASMI fiber orientation predictions. 2)Virginia Tech performed fiber length distribution (FLD) measurements for the samples taken at Locations A, B, C and D from these complex parts using Virginia Tech’s established procedure. Virginia also re-assessed previous data and measured fiber length distributions in the corresponding nozzle purging materials and delivered to PNNL all the measured length data for validating ASMI fiber length predictions. 3)Based on measured fiber orientation data, Autodesk identified the parameters of the anisotropic rotary diffusion reduced strain closure (ARD-RSC) model [1] and provided PNNL with the values of these parameters that were used in ASMI analyses of the complex parts. 4) Magna provided Virginia Tech with additional samples cut out from the 30wt% LCF/PP and 30wt% LCF/PA66 ribbed parts (Figure 1) for fiber length and orientation measurements. 5) Inmore » discussion with Autodesk, PNNL performed 3D ASMI analyses of the 30wt% LCF/PP and 30wt% LCF/PA66 ribbed and non-ribbed complex parts to predict fiber orientations and length distributions in these parts. The issues observed through the analyses regarding fiber orientation distributions profiles and abnormal length distributions were reported to Autodesk. Autodesk is working to resolve these issues. 6) PNNL completed 3D ASMI analyses of the complex parts and compared predicted fiber orientation results at Locations A, B, and C on the non-ribbed parts, and at Locations A, B, C and D on the ribbed parts with the corresponding measured data. PNNL also evaluated the within-15%-agreement criterion using the principal tensile and flexural moduli computed based on predicted vs. measured fiber orientation results. 7) PNNL developed and discussed with Toyota, Magna and PlastiComp a method to perform weight and cost reduction for making the 30wt% LCF/PA66 ribbed part through comparative three-point bending simulations of this part and of similar parts in steel.« less
Authors:
 [1] ;  [1] ;  [2] ;  [2] ;  [3] ;  [3] ;  [4] ;  [5] ;  [6] ;  [7] ;  [7]
  1. Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
  2. Virginia Polytechnic Inst. and State Univ. (Virginia Tech), Blacksburg, VA (United States)
  3. Autodesk, Inc, Ithaca, NY (United States)
  4. Univ. of Illinois, Urbana-Champaign, IL (United States)
  5. Toyota Research Inst. North America, Ann Arbor, MI (United States)
  6. MAGNA Exteriors and Interiors Corp., Aurora, ON (Canada)
  7. PlastiComp, Inc., Winona, MN (United States)
Publication Date:
OSTI Identifier:
1242342
Report Number(s):
PNNL--25163
830403000
DOE Contract Number:
AC05-76RL01830
Resource Type:
Technical Report
Research Org:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org:
USDOE
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE Long carbon fiber, injection molding, thermoplastic, process modeling, fiber orientation, fiber length distribution, tensile modulus, flexural modulus