Numerical simulation of non-isothermal SMC (sheet molding compound) molding

Design of molding tools and molding cycles for sheet molding compounds (SMC) is often expensive and time consuming. Computer simulation of the compression molding process is a desirable approach for reducing actual experimental runs. The focus of this work is to develop a computer model that can simulate the most important features of SMC compression molding, including material flow, heat transfer, and curing. A control volume/finite element approach was used to obtain the pressure and velocity fields and to compute the flow progression during compression mold filling. The energy equation and a kinetic model were solved simultaneously for the temperature and conversion profiles differential scanning calorimetry (DSC) was used to experimentally measure the polymer zation kinetics. A rheometrics dynamic analyzer (RDA) was used to measure the rheological changes of the compound. A series of molding experiments was conducted to record the flow front location and material temperature. The results were compared to simulated flow front and temperature profiles.     

Simulation-based design of sheet molding compound (SMC) compression molding

The design of moding tool and molding cycle for sheet molding compounds (SMC) is often expensive and time consuming. Computer simulation of the compression molding proces is a desirable approach to reduce experimental prototypes. The focus of this work is to develop an automatic optimization scheme utilizing an earlier developed SMC plrocess simulation program which is capable of simulating material flow, heat trensfer, and curing. The proposed scheme reduces computing time by using approximate responses, instead of actual simulated responses, to perform the optimization. The automated optimization package minimizes user intervention during optimal design by creating an automatic link between the optimization and simulation routines. A 2-level factorial design combined with regression analysis is adopted to gather and analyze computed information, and to serve as the approximation formula. Two examples are presented to test the applicability of the optimization scheme.     

Decreasing paint cost for sheet molding compound (SMC) compression molding

Finishing, in most cases, is the most expensive step for manufacturing plastic parts in automotive and truck industry; being electrostatic painting is the desired approach for improved quality. For plastic parts to be painted electrostatically, a conductive primer needs to be applied first. In the case of SMC compression molded parts, in-mold coating (IMC) is the primer material of choice, as it also serves to fill the surface porosity typical in SMC parts. To make the IMC conductive, the current approach is to add carbon black (CB), which results in a black colored primer. In this research, single wall carbon nanotube (SWCNT) was evaluated, as an alternative to CB, to develop a clearer version of conductive IMC. The effect of SWCNTs on both degree of lightness and electrical conductivity was experimentally evaluated. The results indicate that a clearer and slightly more conductive coating than standard IMC can be obtained by adding 0.15 wt% SWCNTs into the base IMC resin, which results in approximately 12.5% paint saving compared to standard IMC. The processability of the modified coating was shown to be only slightly less favorable than standard coating.     

Decreasing the cycle time for in‐mold coating (IMC) of sheet molding compound (SMC) compression molding

In‐mold coating (IMC) is a thermosetting liquid applied to compression molded sheet molding compound (SMC) exterior automotive or truck body panels as an environmentally friendly primer to improve surface quality and make the part conductive for subsequent electrostatic painting. The IMC is injected onto the surface of the SMC then cures and bonds to provide a smooth conductive and protective surface. In IMC as in many other reactive polymer processes, to have short cycle time while maintaining adequate flow time and pot life is required. This allows enough time to fill the mold before solidification. In this study, the effect of inhibitor (p‐benzoquinone), initiator (t‐butyl peroxybenzoate), and mold temperature on the flow and cure time of IMC materials has been experimentally investigated using differential scanning calorimeter. A cure model is developed based on experiments to predict inhibition and cure time. A multiple criteria optimization method was employed to identify the setting parameters of the controllable process variables that provide the best compromise (Pareto frontier [PF]) between flow and cure time. The analysis shows that simultaneous addition of initiator and inhibitor allows the molding to be performed at a higher temperature, which moves the PF toward the ideal location. Hence, minimizes the cure time and maximizes the flow time simultaneously. POLYM. ENG. SCI., 59:1158–1166 2019. © 2019 Society of Plastics Engineers     

Reaction and thermal analysis for SMC (sheet molding compound) molding in complicated geometries

A finite element technique has been developed for coupled reaction and heat transfer analysis in which mass diffusion is negligible. The temperature unknowns are located at nodal points, while the reaction variables (species concentrations, reaction rates) are at the Gauss points in each element. With a mechanistic kinetic model, the SMC (sheet molding compound) cure in 2-D and 3-D geometries was analyzed. The results for plate-and-rib configurations show the progression of cure and heat transfer and the influence of geometry on the progression. The analysis for a flat sheet of SMC in a mold with localized heating using bubblers indicates the thermal interaction between the mold and the curing SMC. Temperature and reaction profiles are given for each case.     

Predicting molding forces during sheet molding compound (SMC) compression molding. I: Model development

Because of its high strength‐to‐weight ratio, corrosion resistance, and low cost, Sheet Molding Compound (SMC) production offers great potential for growth in the automotive and trucking industry. Much attention is now being given to improving the economy of SMC compression molding by reducing the cycle time required to produce acceptable parts in steady production. One of the fastest‐growing applications of Sheet Molding Compound (SMC) compression molding panels is the manufacture of truck body panels. Owing to their large size, the molding forces developed are substantial and have a major influence in the molding cycle. The relevant process models for SMC flow are reviewed and a procedure is developed that can be used to obtain the closing force and calculate the needed material parameters. Experiments were done using commercially made SMC to verify the validity of this model and the compression force was predicted and compared to experimental values for commercially made automotive hoods.     

Fatigue characteristics of high glass content sheet molding compound (SMC) materials

Static and fatigue properties of high glass content sheet molding compound (SMC) materials were studied at various temperatures. It was shown that the matrix plays an important role in both fatigue characteristics and failure mechanism of such randomly oriented short fiber composites. Specifically, vinyl ester matrix shows better fatigue properties and post-fatigue performance than the polyester system considered here.     

Experimental and analytical procedures for flow dynamics of sheet molding compound (SMC) in compression molding

A package of procedures have been developed to collect and analyze the response of dynamic variables such as pressure, temperature, and mold separation during the compression molding of Sheet Molding Compound (SMC). From the dynamic responses, the molding process was found to consist of two regions: the flow and the subsequent curing reaction region. With an R-25 formulation and a mold closing rate of 30 mm/s, these two regions are well separated and the average flow time is not significantly affected by the maturation time for the material up to 30 days. Several mechanical parameters were estimated based on relatively simple flow models. The relationship between the press force, mold separation, and mold closing rate is found to be sensitive to the restrictions of the flow.     

Practical guidelines for predicting steady state cure time during sheet molding compound (SMC) compression molding

The longest part of the molding cycle during SMC compression molding is the curing stage. Thus it is extremely important to be able to predict its duration to estimate the cost of manufacturing a new part. During an SMC molding cycle, the mold surface temperature drops suddenly when it contacts the cold charge. The surface temperature then gradually recovers as heat is conducted from the interior of the mold and the resin releases heat during curing. In general, this exchange of heat remains locally unbalanced, causing a gradual decrease in the local surface temperature. To avoid blistering, the cure time must be increased with consecutive moldings until a steady state value is achieved (t_css). In this paper, we present a series of charts that can be used to estimate the steady state cure time for new parts. These values can then be used to estimate the manufacturing cost.     

Dimensional stability and property gradients in thick sheet molding compound (SMC) sections

The dimensional stability of sample cylinders cured with sheet molding compound pastes was investigated. A significant amount of dimensional change was found for these samples when they were annealed. Furthermore, the amount of change varied with location from the center to the wall along the radial direction of the sample cylinder to form a strain gradient. A series of experiments were then carried out to determine property gradients along the same direction in search of the source of the dimensional instability. It was found that the sample also had a gradient in cure and a gradient in dynamic mechanical properties. But these gradients are not in full agreement. In particular, the gradient of cure appears to be opposite to the direction of the strain gradient, while the gradient of the dynamic mechanical properties coincides with it. These results, therefore, suggest that the dimensional stability may be predominantly governed by the viscoelastic behavior of the material.     

Application of artificial neural networks for the optimal design of sheet molding compound (SMC) compression molding

A sequential design optimization scheme based on artificial neural networks (ANN) is proposed. It is a combination of an ANN model and a nonlinear programming algorithm. The proposed scheme is implemented with network training, optimization, and sheet molding compound (SMC) process simulation in a closed loop. A “cyclic coordinate search” technique is employed to initiate the optimization process, to collect training data for the neural network model, and to perform a preliminary design sensitivity analysis. Emphasis is placed on the development of an integrated, automatic optimization-simulation design tool that does not rely on the designer's experience and interpretation. Testing results based on the design of heating channels in an SMC compression molding tool show that the optimal design can be achieved with fewer data points than other methods, such as factorial design. The efficiency of the ANN method would be greater as the number of design variables grows.     

Air entrapment in sheet molding compounds (SMC)

Entrapped air can commonly lead to large delaminations in thick walled sheet molding compound (SMC) products. In this work different sources of air entrapment in SMC are investigated. The critical process is shown to be the impregnation of the fibers. If no surface active additives are used, large volumes of air may be entrapped in this process, unless the viscosity of the compound is very low. In this situation of poor wetting, the viscosity of the compound during fiber impregnation will critically determine the interlaminar, tensile strength of the product. However, if surface active additives are used, the air escapes entrapment even at relatively high viscosities. The lowering of the viscosity, which is a side effect of the additives, has practically no importance under these conditions of good wetting. Large numbers of small air bubbles are also entrapped during the mixing of the components, but it is shown that these bubbles have very little effect on the mechanical properties of the finished part.     

Predicting molding forces during sheet molding compounds (SMC) compression molding. II: Effect of SMC composition

One of the fastest‐growing applications of SMC compression molding is the manufacture of truck body panels. Because of their large size, the molding forces required are substantial and have a major influence on the molding cycle. Also, as SMC moves towards parts requiring higher strength, the fiber length and percentage by weight of fibers must increase. This will also contribute to larger molding forces. In this paper, a procedure is presented to evaluate the SMC rheological parameters needed to predict molding forces. In addition, the effect of SMC composition on the molding forces is investigated. In particular, we evaluate the effect of reinforcement type (glass versus carbon) and level, filler level and thickener level. It was found that the factors most affecting molding forces are the reinforcement length and level; and the filler level. In addition, it was discovered that for SMC thickened with magnesium oxide, the level of thickener does not affect the molding force.     

Variability in static strengths of sheet molding compounds (SMC)

In this paper, the variability in static strengths of six glass fiber-reinforced sheet molding compounds (SMC) is reported. This variability was shown not to be caused by macroscopic variations in fiber, resin, filler, or void content nor gross fiber anisotropy. Weibull statistics were used to accurately characterize this variability, Random flaw models with the flaws being distributed in the volume, surface, or edge were shown not to predict the observed static strength variability in SMC.     

An experimental study of the dynamics of the curing process of sheet molding compound (SMC) paste

The dynamic curing behavior of sheet molding compound (SMC) has been investigated by using a cylindrical cure reactor. Both thermal and mechanical responses were determined for R-25 SMC paste. The responses from this material were analyzed to determine the chemical and physical transformations that occur during the SMC molding process. The thermal response was obtained from a thermocouple placed along the centerline of the paste sample in the cure reactor. The thermal history at this location shows distinctive stages associated with heat transfer and crosslinking reactions during the cure cycle. The R-25 paste has a precure time of 160 seconds, a reaction time of 25 seconds, and a temperature rise of 134°C. The mechanical response describes the volume change and the pressure of the paste. The displacement curve shows volume changes due to thermal expansion, cure shrinkage, and thermal contraction during the course of a cure cycle. We found a less than 1% shrinkage during the reaction of the R-25 paste. The pressure response of the paste was found to parallel the volume transformation, although it also is strongly influenced by mechanical interactions between the press and the paste.     

Liquid absorption of a sheet molding compound

The absorption of water, isooctane, methanol and ethanol into a sheet molding compound (SMC-R30) at room temperature is studied. The absorption behaviors are shown to be Fickian, with constant diffusion coefficients. Desorption of methanol and ethanol soaked specimens causes considerable surface cracking.     

Curing of compression molded sheet molding compound

A recently developed kinetic model has been applied here to describe the polyester-styrene addition copolymerization. By assuming that the termination step is negligible and the reaction rate between inhibitor and initiator free radical is much, faster than any other reactions, the kinetic mechanism can be simplified to be expressed as a single equation. The parameters, rate constant of initiator decomposition and rate constant of propagation, are estimated from the induction time and the time to the peak exotherm of isothermal differential scanning calorimetry (DSC) curves. Temperature profiles inside plate sections of SMC parts during molding are predicted by a mathematical model in which addition polymerization is coupled with heat transfer. The predicted temperature profiles compare well with the experimental results. The model is also used to predict the cure time of different part thicknesses, mold temperature and initiator concentration. Glass fibers playa role as a heat sink as well as heat conductor during curing. Adding glass fibers to SMC not only lowered the maximum exotherm but also reduced the cure time.     

Dielectric relaxation spectroscopy of sheet molding compound

Dielectric relaxation spectroscopic studies of sheet molding compound from 400 Hz to 100 kHz reveal the relaxation processes that exist in this material. The frequency dependence of SMC is presented and analyzed in terms of different relaxation process models. A transition map of SMC is presented.     

Mechanical characterization of sheet molding compound composites

The present work was aimed at providing basic mechanical property characterization of five different sheet molding compound (SMC) materials with glass content varying from 30 to 65 percent by weight. In particular, the objectives were to find variation in their tensile, flexural, and shear properties along with some information on fabrication-induced anisotropy that may be present in these materials. The flexural properties were measured using three-point bend tests, and double-rail shear tests were conducted for in-plane shear properties. A significant scatter was observed in all the properties, and no conclusive evidence about the fabrication-induced anisotropy was found, Flexural strength of each material was found to be significantly greater than the tensile strength. Finally, some interesting features associated with their tensile and flexural failure modes have also been discussed.