A Comprehensive Assessment of Commercial Process Simulation Software for Compression Moulding of Sheet Moulding Compound

With a growing interest in the application of carbon fibre Sheet Moulding Compound (SMC), a number of commercial software packages have been developed for the simulation of compression moulding of SMC. While these packages adopt different algorithms and meshing strategies, the constitutive material model and processing control are usually adapted from injection moulding process simulation. Little has been done in the literature for assessing the capabilities of these software as design tools, and more importantly, validating the process simulation results using experimental data. This paper aims to provide an independent and comprehensive assessment of existing well-known process simulation software for SMC compression moulding. The selected software will be compared in terms of material models, and available processing settings in order to determine their robustness as a compression moulding design tool. The predictive accuracy of the software will also be assessed by comparing the compression force and filling patterns against the experimental data.

Dynamic failure and crash simulation of carbon fiber sheet moulding compound (CF-SMC)

Carbon fiber sheet moulding compounds (CF-SMC) are a promising class of materials with the potential to replace aluminium and steel in many structural automotive applications. In this paper, we investigate the use of CF-SMC materials for the realization of a lightweight battery case for electric cars. A limiting factor for a wider structural adoption of CF-SMC has been a difficulty in modelling its mechanical behaviour with a computational effective methodology. In this paper, a novel simulation methodology has been developed, with the aim of enabling the use of FE methods based on shell elements. This is practical for the car industry since they can retain a good fidelity and can also represent damage phenomena. A hybrid material modelling approach has been implemented using phenomenological and simulation-based principles. Data from computer tomography scans were used for micro mechanical simulations to determine stiffness and failure behaviour of the material. Data from static three-point bending tests were then used to determine crack energy values needed for the application of hashing damage criteria. The whole simulation methodology was then evaluated against data coming from both static and dynamic (crash) tests. The simulation results were in good accordance with the experimental data. Graphic abstract

Post-impact damage tolerance of natural fibre-reinforced sheet moulding compound

Natural fibre composites are of interest for a wide range of semi-structural applications in the building, construction and automotive sector. For a number of these applications, the evaluation of performance degradation after impact is of some relevance. The present work focused on the influence of fibre volume fraction and fibre surface treatment on the residual load-bearing capability of hemp fibre-reinforced sheet moulding compound (H-SMC) after non-penetrating impacts. Post-impact flexural strength and stiffness of H-SMC decreased linearly with increasing impact energy. At higher impact energy levels, the residual flexural strength of H-SMC improved with increasing fibre volume fraction. However, for the same amount of absorbed energy, the residual strength or damage tolerance capability of glass fibre-reinforced sheet moulding compound was about twice that of H-SMC. Composites based on surface treated hemp fibres showed a slight improvement in residual flexural strength, particularly for systems based on hemp fibres treated with a combined alkaline and silane surface treatment. Surface treated systems showed improved levels of adhesion and increased levels of energy absorption through potential mechanisms such as debonding, pull-out or fibre fibrillation.

Recycling of Commercial E-glass Reinforced Thermoset Composites via Two Temperature Step Pyrolysis to Improve Recovered Fiber Tensile Strength and Failure Strain

Economic and regulatory pressures on the global composites industry have encouraged the research and development of technology for the recycling of fiber reinforced polymer composites. Although significant advancements have been made in the recycling of carbon fiber composites, more progress is needed in the recovery of glass fibers, which make up the overwhelming volume of the composites market. In this study, wind turbine blades and automotive sheet moulding compound (SMC) were subjected to a two temperature step pyrolysis. This multistep process yielded improvements in the recovered E-glass fiber’s tensile strength, by as much as 19%, and strain to failure, by as much as 43%, over a single high temperature step pyrolysis. Despite these gains, pre-pyrolysis fiber measurements indicate that pre-existing damage may inherently limit the quality of glass fiber recoverable from pyrolysis without any post processing.