Fiber Orientation Prediction in Injection Molding

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Solution Overview

Problem

Current injection molding technologies face challenges in accurately predicting fiber orientation distributions in fiber-reinforced thermoplastic composites, particularly in the core region, leading to inconsistencies in mechanical properties and product quality.

Innovation Solution

A molding system incorporating a computing apparatus that generates and updates fiber orientation distributions using a novel rotary diffusional distribution model, independent of shear rate and fiber-polymer interaction, to optimize molding conditions and predict mechanical properties effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional injection molding technology is used, then the molding process can be completed, but the fiber orientation distribution cannot be accurately predicted, leading to inconsistent mechanical properties

Engineering Contradiction:
Improveprediction accuracy of fiber orientation distributionVSAvoidconsistency of mechanical properties
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The system performs CAE simulation before actual injection molding to predict fiber orientation distribution and mechanical properties. This preliminary action allows optimization of molding conditions and fiber parameters before production, avoiding trial-and-error molding and ensuring consistent mechanical properties from the first production run.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system uses iterative feedback between simulation results and actual molding parameters. The CAE simulation predicts fiber orientation and mechanical properties, which are then compared with target specifications, and molding conditions are adjusted accordingly to achieve desired product quality and consistency.

Inventive Principle:
Principle #23Feedback

2Reliability

If trial molding operations are performed to achieve desired mechanical properties, then product quality can be improved, but production time and costs increase

Engineering Contradiction:
Improveproduct quality consistencyVSAvoidmolding cycle time
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The CAE simulation performs preliminary prediction of fiber orientation and mechanical properties before actual molding. This allows all necessary optimizations to be done in the virtual stage, eliminating the need for multiple trial molding operations and significantly reducing production time while ensuring product quality consistency.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system creates a virtual copy of the molding process through CAE simulation. This digital twin allows prediction and optimization of fiber orientation distribution and mechanical properties without physical trial molding, thereby maintaining product quality while eliminating time-consuming trial operations.

Inventive Principle:
Principle #26Copying

3Measurement precision

If complex fiber orientation models that account for shear rate and fiber-polymer interaction are used, then model accuracy may improve, but computational complexity and processing time increase

Engineering Contradiction:
Improvefiber orientation prediction accuracyVSAvoidcomputational model complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The system extracts and uses only the essential factors for fiber orientation prediction that have the greatest impact on mechanical properties. By focusing on the most critical parameters rather than modeling all possible interactions, the system achieves accurate predictions with reduced computational complexity and faster processing time.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The system optimizes the parameters of the fiber orientation model to achieve the best balance between prediction accuracy and computational efficiency. By carefully selecting and tuning model parameters, the system maintains high prediction accuracy while minimizing computational complexity and processing time.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS9919465B1Molding system for preparing an injection molded fiber reinforced composite article
Publication Date: 2018.03.20 CORETECH SYST CO LTD
  • US9919465B1 patent drawing
  • US9919465B1 patent drawing
  • US9919465B1 patent drawing

AI summary

A molding system includes a mold having a mold cavity; a molding machine configured to fill the mold cavity with a composite molding resin including a polymeric material having a plurality of fibers; a computing apparatus connected to the molding machine; and a controller connected to the computing apparatus. The computing apparatus includes a processor configured to generate a previous orientation distribution of the fibers in the mold cavity based on a molding condition for the molding machine, a rotary diffusional distribution of the fibers based on the previous orientation distribution of the fibers, and an updated orientation distribution of the fibers based on the rotary diffusional distribution of the fibers. The controller is configured to control the molding machine to perform an actual molding with the molding condition for injecting the composite molding resin into at least a portion of the mold cavity.