Improved Quality Prediction of Injection Molded Fiber Reinforced

Components by Considering Fiber Orientations

Sascha Pazour

PART Engineering GmbH

pazour@part-gmbh.de

0049 2204 30677 26

© PART Engineering GmbH, www.part-gmbh.de

Plastics

CAE Services & Software

Technical Simulation Contract Simulation Services

in FEA

CAE Staffing Resident Engineers at

customers‘ sites

CAE Software - Process-Structure-Interaction

- Strength & Fatigue Assessment

Metals

S-Life

Elastomers

Mechanical Solver Injection Moulding

Solver

- Moldflow

- Cadmould

- Sigma

- Moldex

- Fluent

- Simpoe

- 3D Timon

- Abaqus

- Ansys

- Radioss

- Nastran

- Marc

- FEMFat

- Ncode

Orientations

Pressures

Temperatures

Wall Thicknesses

Residual Stresses

Shrinkage & Warpage

Fig. 2

material:

PA6+GF30

perpendicular

parallel

Influence of Fiber Orientation onto Material Properties Fig. 3

Fiber Orientations in Short-Fiber-Reinforced Plastics

S1 Shear layer: Fibers oriented parallel to flow direction

S2 Mid layer: Fibers oriented perpendicular to flow direction

Fig. 4

Flow Direction X

X

Cut View X

Flow Direction

S1

S2

S1

Isotropic and Orthotropic Material Models

for Multiaxial Loading

s11

s33

s22

t32

t13

t12

t23 t21

t31

Isotropic Material Model

Orthotropic Material Model

Fig. 5

2*

3* 1*

local system

(orthotropic system)

needs 2 material properties: Tensile Modulus E and Poisson ratio

needs 9 material properties:

Tensile modulii the 3 orthotropic axes E1, E2, E3

Shear modulii the 3 orthotropic planes G12, G13, G23

Poisson ratios 12, 13, 23

Further the position of the orthotropic axes (local element coordinate sytem)

with reference to the global coordinate system is needed

1

3 2 global system

(part coordinate system)

Influence of Weld Lines

weld line

isotropic orthotropic

injection molding simulation simulated fiber directions in

the weld area

radial

displacement

Fig. 6

Fiber Orientation and Anisotropic Material

Fig. 7

Orientations and Degree of Orientations

from Injection Molding Simulation

shear layer mid layer

Fig. 8

Mesh Topology Fig. 9

Converse IM solver mechanical solver

shell (mid-plane/surface) => shell (tria, quad)

shell (mid-plane/surface) => solid (tet, hex)

solid => solid (tet, hex)

unequal meshes

possible

Material Dialog Fig.10

0

200

400

600

800

1000

1200

1400

0 1 2 3 4 5 6

Kra

ft [N

]

Verschiebung [mm]

Messung 1

Messung 2

isotrop

orthotrop

Rotary Valve

material: Grivory HTV 3H1

forc

e [N

]

displacement [mm]

test 1

test 2

FEA isotropic

FEA anisotropic

Fig. 11

Example: Air Intake Manifold

material: Ultramid A3WG6

shear layer mid layer

Fig. 12

Comparison of Eigenfrequencies and Eigenmodes

for Isotropic and Orthotropic Analysis

0

100

200

300

400

500

600

700

800

900

1000

250,00 270,00 290,00 310,00 330,00 350,00 370,00 390,00

eff

ektive M

asse

[g]

Frequenz [Hz]

x-Richtung - isotrop y-Richtung - isotrop z-Richtung - isotrop

x-Richtung - orthotrop y-Richtung - orthotrop z-Richtung - orthotrop

x-direction-isotropic

x-direction-anisotropic

y-direction-isotropic

y-direction-anisotropic

z-direction-isotropic

z-direction-anisotropic

frequency [Hz]

effe

ctive

ma

ss [kg

]

Fig. 13

Benefit of Anisotropic lin.-elast. FEA

• determination of initial part stiffnesses Stiffness

• application in the scope of strength assessments Strength

• unrestricted application in the scope of eigenfrequency extraction and response behavior analyses (due to linearization and small displacements/ amplitudes)

Frequency

• Significantly improved estimation of design limits Design

Fig. 14

Fig. 15

www.part-gmbh.de What´s New?

consider the real part properties

get better predictions of

strength & deformation

by using data already

available

integrates smoothly into

your day-to-day CAE routines

straigthforward easy-to-use

Fig. 16