Process Development for the Ceramic Injection Molding of Oxide Chopped Fiber Reinforced Aluminum Oxide

2017 ◽  
Vol 742 ◽  
pp. 231-237 ◽  
Author(s):  
Metin Tülümen ◽  
Thomas Hanemann ◽  
Michael J. Hoffmann ◽  
Rainer Oberacker ◽  
Volker Piotter
Keyword(s):  
Injection Molding ◽  
Fiber Orientation ◽  
Average Length ◽  
Flow Behavior ◽  
Fiber Content ◽  
Oxide Ceramic ◽  
Fiber Reinforced ◽  
Mechanical Reinforcement ◽  
Ceramic Injection Molding ◽  
Fiber Orientation Distribution

In this study, it was tried to develop a process chain for ceramic injection molding of Al2O3-chopped-fiber reinforced oxide-ceramic-matrix-composite. The feedstocks are compounded at 50 Vol. % filling degree of solid (Al2O3 μ-powder (Taimei Chemicals Co. Ltd.) and 3,2 mm chopped fibers (3M)), in which fiber content varies from 0 Vol. % to 100 Vol. %. As binder system, PE + Paraffin Wax + Stearic Acid are used. The ingredients are compounded in a kneader (Brabender) at 125°C and after the viscosity measurement in the high pressure capillary rheometer at 160°C and certain shear rates, the feedstock is injection molded (Battenfeld) at 160°C, which is followed by debinding process, including chemical (in n-Hexane) and thermal steps, and 2h sintering at different temperatures. Flow paths in the machinery parts, rheological properties of binding system, fiber content and the fiber orientation have significant effect on the flow behavior of the feedstock, fiber -orientation, -distribution & -length, which are crucial to understand the properties of end-parts like mechanical reinforcement of the fibers. The fibers in the sintered parts are ca. 200 μm in average length. The fibers in the feedstock show different orientations depending on the part-geometry and the green bodies have different densities depending on sintering temperature, amount of dispersant and fiber orientation.

Effect of Fiber Orientation on the Tensile Strength in Fiber-Reinforced Polymeric Composite Materials

2005 ◽  
Vol 297-300 ◽  
pp. 2897-2902 ◽  
Author(s):  
Jin Woo Kim ◽  
Jung Ju Lee ◽  
Dong Gi Lee
Keyword(s):  
Tensile Strength ◽  
Composite Material ◽  
Fiber Orientation ◽  
Polymeric Composite ◽  
Orientation Distribution ◽  
Fiber Content ◽  
Fiber Reinforced ◽  
Composite Sheet ◽  
Content Ratio ◽  
Fiber Orientation Distribution

The study for strength calculation of one way fiber-reinforced composites and the study measuring precisely fiber orientation distribution were presented. However, because the DB that can predict mechanical properties of composite material and fiber orientation distribution by the fiber content ratio was not constructed, we need the systematic study for that. Therefore, in this study, we investigated what effect the fiber content ratio and fiber orientation distribution have on the strength of composite sheet after making fiber reinforced polymeric composite sheet by changing fiber orientation distribution with the fiber content ratio. The result of this study will become a guide to design data of the most suitable parts design or fiber reinforced polymeric composite sheet that uses the fiber reinforced polymeric composite sheet in industry spot, because it was conducted in terms of developing products. We studied the effect the fiber orientation distribution has on tensile strength of fiber reinforced polymeric composite material and achieved this results below. We can say that the increasing range of the value of fiber reinforced polymeric composite’s tensile strength in the direction of fiber orientation is getting wider as the fiber content ratio increases. It shows that the value of fiber reinforced polymeric composite’s tensile strength in the direction of fiber orientation 90° is similar with the value of polypropylene’s intensity when fiber orientation function is J= 0.7, regardless of the fiber content ratio. Tensile strength of fiber reinforced polymeric composite is affected by the fiber orientation distribution more than by the fiber content ratio.

Effect of Fiber Content and Fiber Orientation on the Tensile Strength in Glass Mat Reinforced Thermoplastic Sheet

2007 ◽  
Vol 334-335 ◽  
pp. 337-340
Author(s):  
Jin Woo Kim ◽  
Dong Gi Lee
Keyword(s):  
Tensile Strength ◽  
Fiber Orientation ◽  
Orientation Distribution ◽  
Fiber Content ◽  
Fiber Reinforced ◽  
Composite Sheet ◽  
Design Data ◽  
Content Ratio ◽  
Fiber Orientation Distribution ◽  
Glass Mat

The study for strength calculation of one way fiber-reinforced composites and the study measuring precisely fiber orientation distribution were presented. Need the systematic study for the DB that can predict mechanical properties of composite material and fiber orientation distribution by the fiber content ratio was not constructed. Therefore, this study investigated what affect the fiber content ratio and fiber orientation distribution have on the strength of composite sheet after making Glass Mat Reinforced Thermoplastic Sheet by changing fiber orientation distribution with the fiber content ratio. The result of this study will become a guide to design data of the most suitable parts design or fiber reinforced polymeric composite sheet that uses the Glass Mat Reinforced Thermoplastic Sheet in industry part, because it was conducted in terms of developing products. It studied the effect the fiber orientation distribution has on tensile strength of Glass Mat Reinforced Thermoplastic Sheet and achieved this result below. The increasing range of the value of Glass Mat Reinforced Thermoplastic Sheet’s tensile strength in the fiber orientation direction is getting wider as the fiber content increases.

Comparison of recent fiber orientation models in injection molding simulation of fiber-reinforced composites

2018 ◽  
Vol 33 (1) ◽  
pp. 35-52 ◽  
Author(s):  
Huan-Chang Tseng ◽  
Rong-Yeu Chang ◽  
Chia-Hsiang Hsu
Keyword(s):  
Structural Analysis ◽  
Injection Molding ◽  
Fiber Orientation ◽  
Rotational Diffusion ◽  
Deep Understanding ◽  
Fiber Suspension ◽  
Model Parameters ◽  
Fiber Reinforced ◽  
Fiber Orientation Distribution ◽  
Injection Molding Simulation

In the structural analysis of automotive products made of lightweight fiber-reinforced thermoplastics (FRT), the primary mechanical requirement is their relation to the orientation states of fibers. The famous Folgar–Tucker equation of fiber orientation has hitherto been used to predict the skin–shell–core structure of fiber orientation patterns for injection-molded fiber composites. However, this model results in inaccurate predictions regarding the thinner core width. To enhance the reliability of fiber orientation predictions, Tucker and coworkers rigorously derived the reduced strain closure and anisotropic rotary diffusion (ARD) models in relation to the theoretical rheology of fiber suspension. More recently, the improved ARD and retarding principal rate model and the Moldflow rotational diffusion model were developed and made available in the industry dealing with the state-of-the-art software of injection molding simulation. A deep understanding of these fiber models is important for achieving successful FRT structural analysis. In this work, we therefore investigate the accuracy of these fiber orientation models, as well as the changes in fiber orientation distribution related to model parameters and model objectivity.

scholarly journals Warpage Reduction of Glass Fiber Reinforced Plastic Using Microcellular Foaming Process Applied Injection Molding

Polymers ◽  
2019 ◽  
Vol 11 (2) ◽  
pp. 360 ◽  
Author(s):  
Hyun Kim ◽  
Joo Sohn ◽  
Youngjae Ryu ◽  
Shin Kim ◽  
Sung Cha
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Fiber Orientation ◽  
Mechanical And Thermal Properties ◽  
Micro Ct ◽  
Fiber Reinforced ◽  
Foaming Process ◽  
Microcellular Foaming ◽  
Glass Fiber Reinforced ◽  
The Impact

This study analyzes the fundamental principles and characteristics of the microcellular foaming process (MCP) to minimize warpage in glass fiber reinforced polymer (GFRP), which is typically worse than that of a solid polymer. In order to confirm the tendency for warpage and the improvement of this phenomenon according to the glass fiber content (GFC), two factors associated with the reduction of the shrinkage difference and the non-directionalized fiber orientation were set as variables. The shrinkage was measured in the flow direction and transverse direction, and it was confirmed that the shrinkage difference between these two directions is the cause of warpage of GFRP specimens. In addition, by applying the MCP to injection molding, it was confirmed that warpage was improved by reducing the shrinkage difference. To further confirm these results, the effects of cell formation on shrinkage and fiber orientation were investigated using scanning electron microscopy, micro-CT observation, and cell morphology analysis. The micro-CT observations revealed that the fiber orientation was non-directional for the MCP. Moreover, it was determined that the mechanical and thermal properties were improved, based on measurements of the impact strength, tensile strength, flexural strength, and deflection temperature for the MCP.

Prediction for the mechanical property of short fiber-reinforced polymer composites through process modeling method

2018 ◽  
Vol 32 (11) ◽  
pp. 1525-1546 ◽  
Author(s):  
Yue Mu ◽  
Anbiao Chen ◽  
Guoqun Zhao ◽  
Yujia Cui ◽  
Jiejie Feng ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fiber Orientation ◽  
Orientation Distribution ◽  
Fiber Reinforced Composites ◽  
Fiber Reinforced Polymer ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Reinforced Polymer ◽  
Fiber Reinforced Polymer Composites ◽  
Fiber Orientation Distribution

The fiber-reinforced polymer composites are important alternative for conventional structural materials because of their excellent comprehensive performance and weight reduction. The mechanical properties of such composite materials are mainly determined by the fiber orientation induced through practical manufacturing process. In the study, a through process modeling (TPM) method coupling the microstructure evolution and the mechanical properties of fiber-reinforced composites in practical processing is presented. The numerical methodology based on the finite volume method is performed to investigate three-dimensional forming process in the injection molding of fiber-reinforced composites. The evolution of fiber orientation distribution is successfully predicted by using a reduced strain closure model. The corresponding finite volume model for TPM is detailedly derived and the pressure implicit with splitting of operators (PISO) algorithm is employed to improve computational stability. The flow-induced multilayer structure is successfully predicted according to essential flow characteristics and the fiber orientation distribution. The mechanical properties of such anisotropy composites is further calculated based on the stiffness analysis and the Tandon–Weng model. The improvement of mechanical properties in each direction of the injection molded product are evaluated by using the established mathematical model and numerical algorithm. The influences of the geometric structure of injection mold cavity, the fiber volume fractions, and the fiber aspect ratios on the mechanical properties of composite products are further discussed. The mathematical model and numerical method proposed in the study can be successfully adopted to investigate the structural response of composites in practical manufacturing process that will be helpful for optimum processing design.

Process comparison on the microstructure and mechanical properties of fiber-reinforced polyphenylene sulfide using MuCell technology

2018 ◽  
Vol 37 (15) ◽  
pp. 1020-1034 ◽  
Author(s):  
Christoph Lohr ◽  
Björn Beck ◽  
Frank Henning ◽  
Kay André Weidenmann ◽  
Peter Elsner
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Injection Molding ◽  
Fiber Orientation ◽  
Polyphenylene Sulfide ◽  
Injection Molding Process ◽  
Fiber Reinforced ◽  
Molding Process ◽  
Glass Fiber Reinforced ◽  
Foam Injection Molding

The MuCell process is a special injection molding process which utilizes supercritical gas (nitrogen) to create integral foam sandwiches. The advantages are lower weight, higher specific properties and shorter cycle times. In this study, a series of glass fiber-reinforced polyphenylene sulfide foam blanks are manufactured using the MuCell injection molding process. The different variations of the process (low-pressure also known as structural foam injection molding) and high-pressure foam injection molding (also known as “core back expansion,” “breathing mold,” “precision opening,” decompression molding) are used. The sandwich structure and mechanical properties (tensile strength, bending strength, and impact behavior) of the microcellular and glass fiber-reinforced polyphenylene sulfide foams are systematically investigated and compared to compact material. The results showed that the injection parameters (injection speed, foaming mechanism) played an important role in the relative density of microcellular polyphenylene sulfide foams and the mechanical properties. It could be shown that the specific tensile strength decreased while increasing the degree of foaming which can be explained by the increased number of cells and the resulting cell size. This leads to stress peaks which lower the mechanical properties. The Charpy impact strength shows a significant dependence on the fiber orientation. The specific bending modulus of the high-pressure foaming process, however, surpasses the values of the other two processes showing the potential of this manufacturing variation especially with regard to bending loads. Furthermore, a high dependence of the mechanical properties on the fiber orientation of the tested specimens can be found.

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