NetComposites
Attwater

Ticona Use Integrative Simulationfor Effective Fibre Reinforced Component Design

11 April 2012

Ticona is using a calculation method to ensure that glass fibrereinforced components are designed more effectively than with quasi-isotropic linear materialmodels for structural analysis using "integrative simulation" which takes fibreorientation in part design into account.

According to Ticona, optimum design is of major significance for components that are subject to high loads. They explain that during the filling process, fibres in the melt are oriented locally; a fact that has considerable effects on local material properties. The local degrees of orientation and fibredirections that arise are however often not taken into consideration in common calculation methods. Ticona applies the integrative simulation, e.g. in the design of glass fibrereinforced sunroof mounts.

Ticona say that the field of application for fibre-reinforced thermoplastic polymers is constantly increasing, in particular in parts exposed to high loads. Cost and time factors are issues that have played a significant role in increasing the relevance of computer-aided engineering (CAE) in part design in the past years. Standard procedures, based on the finite-element method are frequently used. Ticona say these numeric methods provide information on the components' behaviour under load. But the influence of the fibreorientation of reinforced thermoplastics is considerable and not taken into account in common methods, a factor which plays a significant role for components subject to high or extreme loads. During the mould filling phase of the injection moulding process the fibres are oriented differently in the melt and influence the properties of the subsequent moulded part.

Unlike standard FE calculation methods,Ticona claim thatthe integrative simulation approach takes the influence of the local fibreorientation in the component as well as the elastic-plastic behaviour of the matrix materials. Anisotropic material models are used for this method. These models are based on stress/strain curves that are determined on specimens of the specified material in the main orientation direction of the glass fibres, at a 45° angle and perpendicular to the main direction. The results for the fibredirections are transferred after the mould filling simulation via so-called "mapping" to the structural analysis

Ticona applied the integrative simulation for the design of a glass fibre  reinforced sunroof mount made of Celanex 2300 GV 1/30 and examined the results in terms of accuracy in comparison to experimentally determined values.

They say thesystematic 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.

Ticona say the integrative simulation is an effective procedure for the optimal design of fibre-reinforced component development. The method is particularly suitable for short-fibre reinforced materials and offers major advantages in material savings and cost in complex parts. With the application of the "integrative simulation” Ticona displays consulting competence in the design of components and underscores its position as a provider of overall solutions in the field of material, component design and processing.