DOI QR코드

DOI QR Code

The Effect of Impacted Fracture in Glass Fiber Orientation with Injection Molding & Structural Coupled Analysis

사출-구조 연성해석을 통한 Glass Fiber 배향성이 충격 파괴에 미치는 영향

  • Received : 2016.10.05
  • Accepted : 2016.11.04
  • Published : 2017.01.01

Abstract

The use of engineering plastics in automotive components is increasing with the trend towards improving the car strength and reducing weight. Among the different choices of materials, engineering plastic emerged as the necessary material for achieving lower costs, reduced weight and improved production efficiency. To produce the automotive parts, it is important to predict defect and validation of injection molding prior to design. Injection molding analysis and structural analysis are widely applied as a part of the design process when developing automotive parts. Injection molding analysis, in particular, involves a highly complicated mechanism that requires deep knowledge of polymer properties as well as an analytic approach different from that used for a general isotropic material when the molded material is used as a structural material. This is because the parts made of polymer have pre-stress factors such as intrinsic deformation and residual stress. The most important factors for injection molded plastic products are injection molding condition and cavity design, taking into account ease of molding, mass production and application. Despite optimal injection molding conditions and cavity design, however, glass fiber orientation is critically linked to strength reduction. The application of injection molding and structural coupled analysis provides a low-cost solution for product molding and structural validation, all prior to the actual molding. The purpose of this study involves the validation, pre-study, and solution of defect in injection-molded polymer automotive parts using the simulation software for injection molding and structural coupled analysis. Finally, this thesis provides validation of an injection molding and structural coupled analytic mechanism that can demonstrate the effect of glass fiber orientation on mechanical strength. Design improvement ideas for the injection molded product of PPS (Poly Phenylene Sulfide)+40% glass fiber are also suggested.

References

  1. V. S. Kuksenko and V. P. Tamuzs, Fracture Micromechanics of Polymer Materials, Martinus Nijhoff Publishers, Boston, pp.262-277, 2005.
  2. H. Zhou, Computer Modeling for Injection Molding : Simulation, Optimization and Control, Wiley, New York, pp.214-216, 2013.
  3. M. Tsutsubuchi, T. Hirota, Y. Niwa and T. Shimasaki, Application of Plastics CAE : Focusing on Impact Analysis, Sumitomo Chemical Co., Ltd. Plastics Technical Center, 2014.
  4. G. Potsch and W. Michaeli, Injection Molding An Introduction, Hanser Gardner Publications, Cincinnati, pp.127-131, 1995.
  5. H. Seiichi, Strength Properties of Plastic for Developer, Maruzen, Tokyo, pp.104-108, 2008.
  6. A. J. Pontes, N. M. Neves and A. S. Pouzada, "The Role of the Interaction Coefficient in the Prediction of the Fiber Orientation in Planar Injection Moldings," Department of Polymer Engineering, Univ. do Minho, Vol.24, No.3, pp.358-366, 2002.
  7. A. Redjeb, L. Silva, P. Laure, M. Vincent and T. Coupez, "Three Dimensional Numerical Simulations of Fiber Orientation in Injection Molding," Centre de Mise en Forme des Matreriaux, Vol.124, No.3, pp.366-371, 2002.
  8. Y. Sanomura, K. Hayakawa, M. Mizuno and M. Kawamura, "Effects of Process Conditions on Young's Modulus and Strength of Extrudate in Short-fiber-reinforced Polypropylene," Journal of the Japan Society for Technology of Plasticity, Vol.28, No.1, pp.29-35, 2007.
  9. W. Kim and J. R. Kim, "The Effect of Strength in Glass Fiber Orientation of Vehicle Polymer Product," KSAE Fall Conference Proceedings, pp.1052-1058, 2016.
  10. Autodesk Simulation Moldflow Theory Manual, Autodesk, 2016.
  11. J. Linn, "The Folgar-Tucker Model as a Differential Algebraic System for Fiber Orientation Calculation," Berichte des Fraunhofer, ITWM, No.75, pp.2-4, 2005.
  12. P. Satheesh Kumar, S. Srikari, N. S. Mahesh and S. Reddy, "Structural Analysis of Fiber-filled Plastics with Moulding Process Induced Anisotropy," SAS Tech. Journal., Vol.9, No.2, pp.19-26, 2010.