Molding and Structure Co-Analysis of Injection Molding Composites Considering Heterogeneity in the Thickness Direction

Abstract

During automobile crashes, the main behavior of plastics in the vehicle is bending deformation. Because of this, it is important to accurately calculate the edge stress and allowable stress on structural surfaces. For that purpose, it is necessary to consider the distribution of the fiber orientation angle and degree in the plate thickness direction. In a general coupled analysis for injection-molded materials, a material model is created based on the physical properties obtained from an arbitrary test piece. Therefore, even if the orientation angle in each part to be analyzed is taken into consideration, the degree of orientation is constant in each part, and the degree of orientation distribution in the plate thickness direction is also treated as constant. We tried to improve the accuracy of crash analysis by calculating the edge stress and allowable stress with high accuracy by considering the distribution of orientation angle and degree in the plate thickness direction. For that purpose, we created a model that calculates properties of composite materials from resin and fiber properties, and a process that maps the distribution of orientation angle and degree in the plate thickness direction to each integration point of the shell element in structural molding analysis.