Continuous Simulation of a Continuous-Discontinuous Fiber Reinforced Thermoplastic (CoDiCoFRTP) Compression Molding Process

A virtual process chain for compression molded long fiber-reinforced thermoplastic (LFT) composites with co-molded continuous fiber-reinforced thermoplastics (CoFRTP) consisting of a compression molding and structural simulation step is established. The compression molding simulation considers the three-dimensional initial fiber orientation distribution of the semi-finished LFT plastificate and applies the Moldflow rotary diffusion (MRD) model to predict the reorientation of fibers. The predicted fiber orientations are compared to experimental results obtained from micro computed tomography (µCT) scans. The mapping step from molding to structural simulation allows the transfer of higher order anisotropy. Challenges in homogenizing the effective elastic material behavior of the direct (D-) LFT are discussed. The structural simulation is validated by means of coupon-level fourpoint bending tests on a D-LFT tape sandwich. The predicted bending stiffness shows higher accuracy if the mapped fiber orientation data are considered.