Progress in modeling long glass and carbon fiber breakage during injection molding

Chen, Hongyu; Cieslinski, Mark J.; Baird, Donald G.

doi:10.1063/1.4918422

Cited by 8 publications

(12 citation statements)

References 8 publications

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“…Although the average fiber length of the glass fiber is longer than that of the carbon fiber, the carbon fiber exhibits a higher peak of FLD compared to that of the glass fiber. This finding is consistent with the observation of Chen et al [26].…”

Section: Fiber Breakage Behavior Using Two Types Of Fiberssupporting

confidence: 94%

Simulation prediction of the fiber breakage history in regular and barrier structure screws in injection molding

Huang

Tseng

2017

Polymer Engineering & Sci

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In recent years, the use of long fiber‐reinforced thermoplastics (LFRT) has become one of the most popular materials in lightweight applications. However, the microstructure of the fiber inside the plastic matrix is quite complex, making it hard to fully control the fiber effect in the injection molding process. On the other hand, the screw structure and operation will affect the residual fiber length significantly. However, the mechanism of how the screw influences the fiber breakage is still not yet clear. Thus, in this study, we apply the screw plastication in the injection molding process to investigate the fiber microstructure mechanism. The results show that more severe fiber breakage occurs when the compression force increases abruptly. Generally speaking, the breakage increases from the compression to the metering section. One effective method to reduce the fiber breakage is to increase the channel depths in both the feeding and the metering sections while taking the plastic melt quality into consideration. Moreover, the fiber breakage phenomena for two types of fibers are also investigated. Evidently, carbon fiber is easier to be broken. Its length distribution has a higher peak at the exit of the screw. This discovery is consistent with the experimental results of the current literature studies. POLYM. ENG. SCI., 58:452–459, 2018. © 2017 Society of Plastics Engineers

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Section: Fiber Breakage Behavior Using Two Types Of Fiberssupporting

confidence: 94%

Simulation prediction of the fiber breakage history in regular and barrier structure screws in injection molding

Huang

Tseng

2017

Polymer Engineering & Sci

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“…Many works have dealt with FB of polymer composites processed by injection moulding. 1,2,[5][6][7] Phelps et al's model 6 and its implementation in mould filling simulators, that is Moldflow and Moldex3D, is probably the most relevant approach in this topic. It is a statistical model, which describes the probability of a fibre breaking due to buckling and shearing forces in a flow field.…”

Section: Introductionmentioning

confidence: 99%

Isolation of hydrodynamic parameters for the fibre length attrition in injection-moulded short-fibre polymer composites

Ruiz

Pontes

Ludueña

2021

Journal of Reinforced Plastics and Composites

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A comprehensive study of the fibre breakage mechanisms during mould filling in injection moulding of short-fibre polymer composites requires the isolation of the main parameters promoting fibre length attrition. In this work, hydrodynamic parameters such as injection flow rate and residence time in the range of injection moulding were isolated, and their effect on fibre length attrition was studied. Fibre breakage was quantified by means of a capillary rheometer attached to an injection moulding machine minimising fibre-equipment interactions. Fibre breakage increased linearly as a function of injection flow rate in the range of 30–120 cm3.s−1. It was also found that residence time in the order of milliseconds had a significant effect on fibre breakage. The results shown that longer fibres had less breakage probability, which contradicts the buckling failure theory for brittle fibres in a simple shear flow. This result was attributed to the similar rotation period of the fibres in comparison with the test residence times.

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“…However, fiber breakage and fiber pilling due to incomplete fiber defibration are problems encountered when long-fiber-reinforced resin is injected in an injection molding context. These problems occur during resin material plastication in the heating cylinder [1][2][3][4][5][6][7] and when the resin passes through the narrow flow path of the nozzle through the reciprocating screw's check-ring [8][9][10][11][12]. When evaluating the strength of injection-molded thermoplastic fiber-reinforced resin, high average fiber length does not always lend the molded product high mechanical strength.…”

Section: Introductionmentioning

confidence: 99%

Visualization Analysis of Defibration and Distributive Uniformity of Fibers in Long-fiber-reinforced, Injection-Molded Resins

Owada

et al. 2020

Polymers

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The pursuit of mechanical strength in the injection molding of long-fiber-reinforced resins continues to pose major challenges, namely (1) improvement of fiber defibration and fiber distribution and (2) suppression of fiber breakage during the molding machine’s plastication process. In the present study, a new defibration and distribution evaluation mold is developed to quantitatively evaluate the defibration and distribution of long fibers in nozzle-injected resin. A quantitative analysis method using this evaluation mold is proposed for visualizing and observing long-glass-fiber-reinforced resin up to 30 wt % and long carbon fiber-reinforced resin up to 10 wt %. The method, based on the intensity of light transmitted from a backlight source, is also used to evaluate areas of undefibrated fiber pilling and for evaluating the influence of molding conditions on fiber defibration and uniform distribution. The results clarify that fiber distribution non-uniformity can be reduced by improving the concentration adjustment procedure for the dry blending of high-concentration pellets. Additional results show that fiber defibration and distributive uniformity can be improved by applying high back pressure.

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Progress in modeling long glass and carbon fiber breakage during injection molding

Cited by 8 publications

References 8 publications

Simulation prediction of the fiber breakage history in regular and barrier structure screws in injection molding

Simulation prediction of the fiber breakage history in regular and barrier structure screws in injection molding

Isolation of hydrodynamic parameters for the fibre length attrition in injection-moulded short-fibre polymer composites

Visualization Analysis of Defibration and Distributive Uniformity of Fibers in Long-fiber-reinforced, Injection-Molded Resins

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