An Integrated Approach Linking Process to Structural Modeling With Microstructural Characterization for Injections-Molded Long-Fiber Thermoplastics
The objective of our work is to enable the optimum design of lightweight automotive structural components using injection-molded long fiber thermoplastics (LFTs). To this end, an integrated approach that links process modeling to structural analysis with experimental microstructural characterization and validation is developed. First, process models for LFTs are developed and implemented into processing codes (e.g. ORIENT, Moldflow) to predict the microstructure of the as-formed composite (i.e. fiber length and orientation distributions). In parallel, characterization and testing methods are developed to obtain necessary microstructural data to validate process modeling predictions. Second, the predicted LFT composite microstructure is imported into a structural finite element analysis by ABAQUS to determine the response of the as-formed composite to given boundary conditions. At this stage, constitutive models accounting for the composite microstructure are developed to predict various types of behaviors (i.e. thermoelastic, viscoelastic, elastic-plastic, damage, fatigue, and impact) of LFTs. Experimental methods are also developed to determine material parameters and to validate constitutive models. Such a process-linked-structural modeling approach allows an LFT composite structure to be designed with confidence through numerical simulations. Some recent results of our collaborative research will be illustrated to show the usefulness and applications of this integrated approach.
- Research Organization:
- Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- AC05-76RL01830
- OSTI ID:
- 940992
- Report Number(s):
- PNNL-SA-60601; VT0505000; TRN: US200824%%326
- Resource Relation:
- Conference: 40th International SAMPE Technical Conference (ISTC)
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
FIBERS
MICROSTRUCTURE
ORIENTATION
PROCESS CONTROL
THERMOPLASTICS
REINFORCED PLASTICS
COMPUTER-AIDED DESIGN
FINITE ELEMENT METHOD
Applications-Automotive
Injection Molding
Characterization
Fiber Composite Materials-Long Fiber Systems
Injection Molding
Micromechanics
Modeling Methodology
Structural Analysis