Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites

In-situ thermoforming and overmolding of continuous fiber-reinforced thermoplastic composites by hybrid injection molding enables the mass production of thermoplastic lightweight structures with a complex geometry. In this study, the anisotropic mechanical behavior of such hybrid injection molded sh...

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Autores principales:	Patrick Hirsch, Marianne John, Daniel Leipold, André Henkel, Sylvia Gipser, Ralf Schlimper, Matthias Zscheyge
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	numerical simulation hybrid injection molding continuous fiber-reinforced thermoplastics Organic chemistry QD241-441
Acceso en línea:	https://doaj.org/article/7a873fbaead843828eb5762406801f56
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spelling	oai:doaj.org-article:7a873fbaead843828eb5762406801f562021-11-11T18:48:57ZNumerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites10.3390/polym132138462073-4360https://doaj.org/article/7a873fbaead843828eb5762406801f562021-11-01T00:00:00Zhttps://www.mdpi.com/2073-4360/13/21/3846https://doaj.org/toc/2073-4360In-situ thermoforming and overmolding of continuous fiber-reinforced thermoplastic composites by hybrid injection molding enables the mass production of thermoplastic lightweight structures with a complex geometry. In this study, the anisotropic mechanical behavior of such hybrid injection molded short and continuous fiber-reinforced thermoplastics and the numerical simulation of the resulting mechanical properties under flexural loading were investigated. For this, the influence of the volume flow rate between 25 and 100 cm<sup>3</sup>/s during injection molding of a PP/GF30 short fiber-reinforced overmolding material was studied and showed a strong effect on the fiber orientation but not on the fiber length, as investigated by computer tomography and fiber length analysis. Thus, the resulting anisotropies of the stiffness and strength as well as the strain hardening investigated by tensile testing were considered when the mechanical behavior of a hybrid test structure of short and continuous fiber-reinforced thermoplastic composites was predicted by numerical simulations. For this, a PP/GF60 and PP/GF30 hybrid injection molded test structure was investigated by a numerical workflow with implemented injection molding simulation data. In result, the prediction of the mechanical behavior of the hybrid test structure under flexural loading by numerical simulation was significantly improved, leading to a reduction of the deviation of the numerically predicted and experimentally measured flexural strength from 21% to 9% in comparison to the isotropic material model without the implementation of the injection molding data.Patrick HirschMarianne JohnDaniel LeipoldAndré HenkelSylvia GipserRalf SchlimperMatthias ZscheygeMDPI AGarticlenumerical simulationhybrid injection moldingcontinuous fiber-reinforced thermoplasticsOrganic chemistryQD241-441ENPolymers, Vol 13, Iss 3846, p 3846 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	numerical simulation hybrid injection molding continuous fiber-reinforced thermoplastics Organic chemistry QD241-441
spellingShingle	numerical simulation hybrid injection molding continuous fiber-reinforced thermoplastics Organic chemistry QD241-441 Patrick Hirsch Marianne John Daniel Leipold André Henkel Sylvia Gipser Ralf Schlimper Matthias Zscheyge Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites
description	In-situ thermoforming and overmolding of continuous fiber-reinforced thermoplastic composites by hybrid injection molding enables the mass production of thermoplastic lightweight structures with a complex geometry. In this study, the anisotropic mechanical behavior of such hybrid injection molded short and continuous fiber-reinforced thermoplastics and the numerical simulation of the resulting mechanical properties under flexural loading were investigated. For this, the influence of the volume flow rate between 25 and 100 cm<sup>3</sup>/s during injection molding of a PP/GF30 short fiber-reinforced overmolding material was studied and showed a strong effect on the fiber orientation but not on the fiber length, as investigated by computer tomography and fiber length analysis. Thus, the resulting anisotropies of the stiffness and strength as well as the strain hardening investigated by tensile testing were considered when the mechanical behavior of a hybrid test structure of short and continuous fiber-reinforced thermoplastic composites was predicted by numerical simulations. For this, a PP/GF60 and PP/GF30 hybrid injection molded test structure was investigated by a numerical workflow with implemented injection molding simulation data. In result, the prediction of the mechanical behavior of the hybrid test structure under flexural loading by numerical simulation was significantly improved, leading to a reduction of the deviation of the numerically predicted and experimentally measured flexural strength from 21% to 9% in comparison to the isotropic material model without the implementation of the injection molding data.
format	article
author	Patrick Hirsch Marianne John Daniel Leipold André Henkel Sylvia Gipser Ralf Schlimper Matthias Zscheyge
author_facet	Patrick Hirsch Marianne John Daniel Leipold André Henkel Sylvia Gipser Ralf Schlimper Matthias Zscheyge
author_sort	Patrick Hirsch
title	Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites
title_short	Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites
title_full	Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites
title_fullStr	Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites
title_full_unstemmed	Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites
title_sort	numerical simulation and experimental validation of hybrid injection molded short and continuous fiber-reinforced thermoplastic composites
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/7a873fbaead843828eb5762406801f56
work_keys_str_mv	AT patrickhirsch numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites AT mariannejohn numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites AT danielleipold numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites AT andrehenkel numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites AT sylviagipser numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites AT ralfschlimper numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites AT matthiaszscheyge numericalsimulationandexperimentalvalidationofhybridinjectionmoldedshortandcontinuousfiberreinforcedthermoplasticcomposites
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Numerical Simulation and Experimental Validation of Hybrid Injection Molded Short and Continuous Fiber-Reinforced Thermoplastic Composites

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