The process and microstructure modeling of long-fiber thermoplastic composites

Abstract

Interest in thermoplastic matrix composites has increased in recent years due to several advantages of these materials, including high volume process ability, recyclability, superior damage tolerance and fracture toughness, and ability to produce complex shapes. Among thermoplastic composites, long-fiber thermoplastics (LFTs) are finding increased use in the automotive and transportation sector. Predictive process and material characterization tools are much needed in industry to minimize expensive tooling/process trials and to improve the design avenues for parts produced using LFTs. The current work focuses on finite element simulation of LFT materials for two scenarios: first, process modeling of LFTs to evaluate the flow of fiber-filled viscous charge during compression molding and the resulting fiber orientation prediction and, second, modulus prediction of LFT materials accounting for fiber orientation and distribution. Together these tools provide insight into the process and performance characteristics of LFT materials.