注射成型时纤维取向的计算机模拟

基于Ｈｅｌｅ－Ｓｈｏｗ流动，采用Ｄｉｎｈ－Ａｒｍｓｔｒｏｎｇ本构模型，本文研究了一种数值方法用来模拟中等浓度短纤维增强塑料在注塑成型过程中纤维的取向状态。纤维的取向状态由取向椭球的投影表示，而取向椭球由计算二阶取向张量得到。本文推导了注射成型过程中纤维取向 概率分布函数，并将模拟的结果与以前研究者所做的实验进行了比较。     

GMT流动成型纤维取向研究

GMT材料流动成型后玻纤在平面内发生取向，导致模压件呈各向异性，本研究从成型后制品上取样烧尽树脂，由扫描仪获取纤维数值图像，用Photoshop软件将图像反相，增强，再利用MATLAB软件确定纤维取向分布，研究表明，GMT单向流动成型时纤维沿流动方向取向，随流动距离增大，取向趋向更为明显，而均匀双向拉伸流动纤维取向程度较小，与片材相比，材料力学性能沿取向方向增大，但垂直取向方向材料性能变差。     

纤维解取向行为的粘弹性分析

建立了高分子纤维材料的自由状态的二元件弹簧与粘壶的串联粘弹性模型,对解取向的热力学本质及动力学方程进行了推导,用这一模型可以合理诠释解取向过程的粘弹性本质。通过粘弹本构方程的推导,研究了解取向过程中的瞬时应力和收缩应变与温度及时间的函数关系。结果表明,纤维解取向的自发倾向取决于纤维的初始内应力和环境温度,解取向环境的温度越高,时间越长,纤维解取向时的内部瞬时内应力越小,而收缩应变越大,lnσ(t)和ln[-(γ(t))]呈现对时间的一次函数关系。高分子链本身的粘弹特性如相对分子质量、分子链的柔性,以及微观松弛时间等都将影响纤维的解取向行为。     

长纤维增强聚合物注塑流动纤维取向分布数值模拟

基于Hele-Shaw流动模型及广义牛顿流体本构方程,采用ARD-RSC取向模型,建立了长纤维增强聚合物注塑成型流动数学模型。以方形薄板为研究对象,运用Moldflow对注塑流动过程进行模拟,研究注射时间、熔体温度、模具温度和保压压力对纤维取向及分布的影响。结果表明,注射时间对纤维取向的影响最为显著,随着注射时间延长,纤维取向值增加;随着熔体温度或模具温度的升高,纤维取向值减小;保压压力对纤维取向的影响与速度/压力转换点有关。     

短纤维增强聚丙烯中纤维取向分布的测定

报导了一种用于测定短玻璃纤维增强聚丙烯复合材料中纤维取向的快速、简便、准确的新方法，该方法采用氢氟酸刻蚀玻璃纤维提高相差，使得复合材料样品截面上的纤维取向可以直接在相差光学显微镜下观测。采用该方法测定了注射成型的复合材料中纤维的取向分布，实验结果与计算机模拟的结果基本一致。     

纤维含量对注塑制品残余应力影响的数值模拟

采用短纤维增强尼龙6复合材料,对带有半圆形缺口平板制件的注塑成型过程进行了模拟。以制件半圆形缺口附件的5个单元为研究对象,分别获得了不同位置上纤维取向和制件脱模时应力沿厚度方向上的变化,深入讨论了模具外形、纤维含量变化对纤维取向以及残余应力的影响。研究结果表明,随着纤维含量的增加,纤维间相互作用系数Ci减小,取向程度升高,皮层取向厚度减小,芯层取向厚度增加;纤维含量越高,制品冷却时沿厚度方向的压力幅值越大,残余应力沿厚度分布幅值也越大;制件形状的改变,影响了熔体流经此处的流动状态,同时也影响了缺口附件纤维取向以及残余应力。     

PAN基碳化纤维制备过程中纤维的晶态结构研究

采用X射线二维衍射图像和面扫描法对PAN碳化纤维制备过程中各阶段纤维进行了结构表征,揭示了干喷湿纺原丝在预氧化和碳化阶段各纤维晶区取向和晶态结构的差异。结果表明,利用赤道方向二维衍射图,可直观地观察到各纤维在不同阶段取向度以及结晶度的演变规律。与原丝相比,205℃预氧化纤维的取向度、晶粒尺寸以及结晶度都增大,晶面间距无明显变化。235℃预氧化纤维的取向度、晶粒尺寸以及结晶度都减小,晶面间距增大。与原丝以及预氧化纤维相比,碳化阶段纤维的取向度、晶粒尺寸、结晶度以及晶面间距都明显减小。     

玻纤增强聚丙烯多腔微注塑中纤维取向与流动偏移

采用3D模拟技术和各项异性旋转扩散-诱导应变闭合(ARD-RSC)等模型以及集成式热电偶传感器温度测量系统和可视化全息示踪技术,对多型腔微注塑成型过程中玻纤增强聚丙烯(GFRPP)熔体在流道中的纤维取向、温度和流动速度偏移现象进行模拟和分析。结果表明,低速注射时,GFRPP熔体中纤维取向明显,流道表层区域的纤维取向程度大于芯层区域的纤维取向,存在着明显的、不对称的表层-芯层-表层结构,纤维取向加剧了塑料熔体前沿温度与流动速度的向下偏移。高速注射时,纤维取向仍然存在不对称的表层-芯层-表层结构,但比低速注射时不明显得多,纤维取向对熔体前沿高温区和流动速度向下侧偏移幅度的影响也较低速注射时更大。即GFRPP熔体在不同注射速度下熔体的流动速度、流动状态、温度变化相互作用与影响,使得熔体的纤维取向,流动速度、温度分布产生偏移,导致流道系统和型腔充型不均衡。     

短纤维增强塑料注射成型中三维纤维取向的数值预测

在建立聚合物熔体在型腔中充填流动以及短纤维取向的数学模型的基础上，对平面薄壁型腔内纤维取向的预测算法加以推广，提出适合于具有任意几何形状的三维薄壁型腔内纤维取向的数值预测技术，并且给出一个熔体充填三维薄壁壳体状型腔的算例，预测的结果与由流动引起的纤维取向定性规律相符合。     

纤维类型及取向对纤维-UHPC基体拔出性能影响研究

纤维与基体之间的粘结能力和机械锚固作用是基体将荷载传递给纤维的决定因素之一,不同类型的纤维和取向在拉拔时的受力形式和破坏形式决定试件承载能力。采用单根纤维拉拔试验探究了纤维类型、取向对超高性能混凝土(UHPC)界面拉伸性能的影响。结果表明:随着纤维取向的增加拔出荷载先增大后减小,在45°时拔出荷载达到最大值;随着纤维取向增加,纤维拔出时对基体破坏面积增大,纤维拔出时对于基体的破坏能力:波纹线>端勾型>直线型。由第一峰值荷载分析,波纹型钢纤维相比于直线型和端勾型钢纤维更容易脱黏。对纤维拔出时进行力学行为分析,波纹型钢纤维和端勾型钢纤维拔出过程中首先发生纤维屈服,随着荷载持续基体产生破坏,直线型钢纤维在拔出过程中最先发生纤维与基体脱黏。     

纤维增强塑料注塑成型集成仿真建模

注射成型过程中的熔体流动分析、纤维断裂和纤维取向预测紧密相关, 并且具有重要的 工程应用价值, 因此对其进行集成仿真是十分有意义的。本文在分析各自特点的基础上, 提出注塑 流动、纤维断裂和纤维取向集成仿真模型, 可对充填和后充填阶段的可压缩流体的非对称流动, 以 及由于熔体流动引起的纤维断裂、三维纤维取向行为进行统一建模, 并且熔体流动和纤维取向相 互耦合。      

Eco-strategy of numerical simulation for fiber assembly orientation in an abrupt planar contraction flow

The objective of the present work is to well understand the mechanism of fiber assembly orientation in various flows involving the processing of composite materials. The evolution of the orientation of fiber assembly in a 4:1 planar contraction flow has been numerically simulated using a computer-friendly-strategy of numerical solution proposed in the work to considerably reduce a computational time: first, fiber suspension flow through a 4:1 planar contraction geometry is numerically simulated on the basis of the co-linear alignment approximation of fibers: secondly, 3-D orientation of a large number of fibers is evaluated by computing the Jeffery equation along the streamlines in the above fiber suspension flow: finally, the evolution of the orientation of fiber assembly can be predicted. The predictions would be feasible for the practical purpose in a fiber composite processing.     

High Performance Materials from Oriented Plastics

Molecular orientation of polymer chains affects considerably the final properties of plastic products, such as stiffness, creep and impact resistance, barrier properties and transparency. Different orientation processes, such as solid state extrusion, die-drawing and roll-drawing are currently being investigated in order to produce parts with large dimensions. Examples include the die-drawing process for the obtention of oriented tubes and shapes, roll-drawing for flat and simple geometry profiles as well as uniaxial and biaxial solid state extrusion. These processes have been used successfully to form different materials, from polyolefins to engineering and specialty resins, and mechanical properties comparable to fiber reinforced plastics have been achieved. Solid state forming was performed in our laboratories on several polymeric materials using rolling, roll-drawing and solid state extrusion. Significant improvements in the mechanical behavior were observed and materials with tensile modulus and strength above 10 GPa and 400 MPa, respectively, were obtained. An improvement in the transverse mechanical properties was also observed for the roll-drawn polymers.     

Processing and characterization of aligned vapor grown carbon fiber reinforced polypropylene

This investigation describes a method for aligning vapor grown carbon nano-fibers suspended in a polymer flow during extrusion to produce an improved thermoplastic composite. A twin-screw extruder was used to shear mix and extrude fiber/polypropylene mixtures through a converging-annular die that generates fiber alignment along the flow direction. The degree of fiber alignment was quantified by using X-ray diffraction. It was shown that fiber alignment could be improved by increasing the residence time in the die channel. Tensile specimens were fabricated by molding the extruded strands and the strength properties of the aligned samples increased with fiber content. The tensile strength improved with greater fiber orientation, however, more fiber alignment had little affect on the modulus. The addition of vapor grown carbon nano-fiber also increased the thermal conductivity and decreased the electrical resistivity.     

Prediction of fiber orientation structure for injection molded short fiber composites

Structure of fiber orientation in injection molded short fiber composites is predicted by the numerical analysis. To analyze the packing stage as well as the filling stage, a compressible generalized Hele-Shaw model is adopted. A numerical scheme free from coordinate transformation is developed for three-dimensional shell-like geometry. Flow-induced fiber orientation can be predicted by solving evolution equations for the orientation tensor with a suitable closure approximation. Fibers are mainly oriented toward the flow direction near the top cavity wall due to high shear rates, while they are randomly oriented near the centerline of cavity where low shear rates prevail. Thus, the molded parts show the skin-core structure of orientation. Structure of fiber orientation continues to change during the packing stage due to additional velocity gradients – which are likely to align fibers more towards the flow direction. Electronic Publication     

Geometrical analysis of woven fabric microstructure based on micron-resolution computed tomography data

The global mechanical properties of textiles such as elasticity and strength, as well as transport properties such as permeability depend strongly on the microstructure of the textile. Textiles are heterogeneous structures with highly anisotropic material properties, including local fiber orientation and local fiber volume fraction. In this paper, an algorithm is presented to generate a virtual 3D–model of a woven fabric architecture with information about the local fiber orientation and the local fiber volume fraction. The geometric data of the woven fabric impregnated with resin was obtained by micron-resolution computed tomography (μCT). The volumetric μCT-scan was discretized into cells and the microstructure of each cell was analyzed and homogenized. Furthermore, the discretized data was used to calculate the local permeability tensors of each cell. An example application of the analyzed data is the simulation of the resin flow through a woven fabric based on the determined local permeability tensors and on Darcy’s law. The presented algorithm is an automated and robust method of going from μCT-scans to structural or flow models.     

挤出成型GFRC板的纤维取向分布和轴拉性能

挤出成型工艺生产玻璃纤维增强水泥板(GFRC)时,纤维在螺旋推挤力和速度剪力的作用下,大部分纤维能在挤出方向上形成定向排列,轴拉强度相对较高。而垂直于挤出方向的纤维分布相对较少,力学性能也相对较差。试验结果表明,当纤维含量较低时,绝大部分纤维沿挤出方向分布,此时,平行挤出方向的轴拉强度远大于垂直挤出方向。纤维掺量较高时,垂直挤出方向上的纤维分布量大大增加,相应的轴拉强度几乎与平行挤出方向相等。此外,存在一个纤维掺量饱和点,超过此掺量,平行纤维方向的轴拉强度不再随掺量的增加而提高,但有利于改善GFRC板的韧性和轴拉破坏形式。