Advanced modeling and simulation of sheet moulding compound (SMC) processes
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IJMF 10TH ANNIVERSARY - ADVANCES IN MATERIAL FORMING
Advanced modeling and simulation of sheet moulding compound (SMC) processes M. Perez1 · D. Prono1 · C. Ghnatios2 · E. Abisset3 · J. L. Duval1 · F. Chinesta4 Received: 27 April 2019 / Accepted: 12 August 2019 © Springer-Verlag France SAS, part of Springer Nature 2019
Abstract SMC processes involve a highly concentrated dispersion of chopped fibres into a resin, placed into a preheated mould, that closes rapidly (about 40 mm/s) squeezing the reinforced resin, inducing the mould filling accompanied of the fibres induced orientation that influences the mechanical properties of the final part. Several issues compromises its efficient numerical simulation, among them: (i) the modeling of flow kinematics able to induce eventual fibres/resin segregation, (ii) the confined fibres orientation evolution and its accurate prediction, (iii) local dilution effects, (iv) flow bifurcation at junctions and its impact on the fibres orientation state, (v) charge / mould contact and (vi) parametric solutions involving non-interpolative fields. The present paper reports advanced modeling and simulation techniques for circumventing, or at least alleviating, the just referred difficulties. Keywords SMC · Confined orientation · Friction · Parametric solutions · PGD
Introduction Structural parts traditionally made with metals are being replaced by composites and reinforced polymers to take F. Chinesta
[email protected] M. Perez [email protected] D. Prono [email protected] C. Ghnatios [email protected] E. Abisset [email protected] J. L. Duval [email protected] 1
ESI Group, 3bis rue Saarinen, 94528 Rungis Cedex, France
2
Norte Dame University-Louaize, Mechanical Engineering Department, Zouk Mosbeh, Lebanon
3
I2M, ENSAM ParisTech, Esplanade des Arts et M´etiers, 33405 Talence Cedex, France
4
ESI Group chair, PIMM Lab, ENSAM ParisTech, 151 Boulevard de l’Hˆopital, 75013 Paris, France
advantage of the weight reduction or the more flexible manufacturing processes. When mechanical performances are searched, continuous reinforcements are being considered, however, many times mechanical properties must be complemented with a variety of functionalities. In that case, using discontinuous reinforcement, ranging from the nano and micro scales to the scale of few centimeters, seem an appealing alternative for enhancing functionalities while keeping affordable forming processes. Thus reinforced polymers allow equivalent properties than technical polymers while implying cheaper materials and processes. However, these properties are strongly affected by the forming process itself, because of the induced fibre distribution and orientation. The present paper addresses the flow of highly concentrated resins, encountered in SMC processes, widely considered in the automotive industry because of its high volume capabilities. The modeling of such processes entails many difficulties, among them the flow and orientation occurring in t
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