New Methods for Compression Molding Simulation and Component Strength Validation for Long Carbon Fiber Reinforced Thermoplastics

Composite materials like fiber reinforced plastics (FRP) are becoming more widely used in the automotive industry and have been found very effective in reducing vehicle weight. Recently, long carbon fiber reinforced thermoplastics are increasingly being used for lightweight structural parts with high stiffness, strength and energy absorption performance. Compression molding is considered one of the most efficient manufacturing processes to mass produce FRP parts for automotive applications. Compression molding can form FRP into complex shapes with relatively low manufacturing cost and short process time. However, this often generates unwanted fiber orientation, uneven distribution of fibers and fillers, weld lines and matrix rich regions. These forming effects strongly affect mechanical strength. To analyze these complex phenomena, LSTC and JSOL developed new compression molding simulation techniques for long fiber reinforced plastics using a beam-in-adaptive EFG coupling function in LS-DYNAⓇ. In this paper, a compression molding simulation for long carbon fiber reinforced thermoplastics is introduced and new component strength analysis method with a beam-in-SPG coupling model using deformed beams calculated in the compression molding simulation is presented.