Simulation technology for glass fiber composite design

Ticona Engineering Polymers has made "integrative simulation" technology available to improve the accuracy of computing fiber-reinforced components under load.

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Ticona Engineering Polymers (Florence, Ky.) has announced the global availability of “integrative simulation” technology that can help customers design complex glass fiber-reinforced parts. Since 2009, Ticona has worked with e-Xstream engineering DIGIMAT material and structure modeling tools to link Autodesk Moldflow plastic injection molding simulation tools with ANSYS Inc. structural analysis to improve the accuracy of computing fiber-reinforced components under load.
Labeled integrative simulation, because it integrates processing simulation data in the computation of the component, this technology can be used to design complex parts that use short- and long-fiber-reinforced thermoplastics. Ticona says that by systematically comparing simulation and experimental results, the company has shown this procedure can move simulation forecasts closer to the actual experimental gradients.

During the mold-filling phase of the injection molding process, fibers typically are oriented in different directions within the part as a function of the melt flow. Ticona says the influence of this local fiber orientation is substantial and not taken into account in common numerical methods, a factor that plays a significant role for components subject to high or extreme loads. Iintegrative simulation takes into account the influence of the local fiber orientation in the component as well as the elastic-plastic behavior of the matrix materials. Non-linear anisotropic material models are used for this method. Models are based on stress/strain curves that are determined on specimens of the specified material in the main orientation direction of the glass fibers, at a 45° angle and perpendicular to the main direction. The results for the fiber directions are transferred after the mold filling simulation via so-called "mapping" to the structural analysis.

Ticona applied the integrative simulation for the design of a glass fiber reinforced sunroof mount made of Celanex 2300 GV1/30 PBT and examined the results in terms of accuracy in comparison to experimentally determined values. The systematic comparison of this non-linear anisotropic simulation displays a considerably improved compliance with experimentally determined values. The resulting simulation for the sunroof mount illustrates that the integrative simulation provides more accurate results than common linear isotropic calculations methods.