An integrated approach linking process to structural modeling with microstructural characterization for injection-molded long-fiber thermoplastics

Ba Nghiep Nguyen, Satish K. Bapanapalli, Mark T. Smith, Vlastimil Kunc, Barbara J. Frame, Robert E. Norris, Jay H. Phelps, Charles L Tucker, Xiaoshi Jin, Jin Wang

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

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.

Original languageEnglish (US)
Title of host publicationSAMPE Fall Technical Conference and Exhibition - Multifunctional Materials
Subtitle of host publicationWorking Smarter Together, SAMPE '08
StatePublished - Dec 1 2008
Event2008 SAMPE Fall Technical Conference and Exhibition - Multifunctional Materials: Working Smarter Together, SAMPE '08 - Memphis, TN, United States
Duration: Sep 8 2008Sep 11 2008

Publication series

NameInternational SAMPE Technical Conference

Other

Other2008 SAMPE Fall Technical Conference and Exhibition - Multifunctional Materials: Working Smarter Together, SAMPE '08
CountryUnited States
CityMemphis, TN
Period9/8/089/11/08

Keywords

  • Applications-automotive
  • Fiber composite materials-long fiber systems
  • Injection molding
  • Micromechanics
  • Modeling methodology

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

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