Bridging the Gap Between Autodesk® Simulation Moldflow® and Nonlinear Structural Finite Element Analysis of Molded Composites Parts

The market for plastic composites is increasing. All types of reinforcements are found, from short to long to continuous fibers. Long-fiber-reinforced plastics can be processed with injection molding and exhibit good performance in energy absorption. This makes them interesting for crash applications for the automotive industry. However, moving to long fibers also means moving towards complexity. Isolated long fibers exhibit a wavy shape, changing stiffness properties of the composite. Straight fibers are found in bundles, influencing the failure of the material. Injection molding of long fibers can lead to fiber breakage. This has to be taken into account when designing plastic parts using simulation. This class provides insight into an approach using DIGIMAT™, with the goal to provide a material model for long-fiber-reinforced plastics. We will present investigations of the material with first approaches to couple structural mechanics with Autodesk Simulation Moldflow software, including prediction of fiber breakage.