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.     

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.     

Powder coating of sheet molding compound (SMC) body panels

Sheet Molding Compound (SMC) compression molded parts are prone to porosity. During top coat baking, trapped air in the surface porosity expands and often blows through the paint leaving unacceptable craters in the final finish. The accepted solution to this problem in the SMC industry is to use a coating compound on the SMC part. The coating compound (called in‐mold coating (IMC)) is injected and cured on the SMC molding after its cure is complete, but before removing it from the mold. Another potential solution is to powder coat the parts once they have been de‐molded. While powder coating adds time to the process, it is performed outside of the mold and frees the mold for the next molding cycle earlier than if the IMC process is used. In the present paper, we develop a simplified model for the powder coating of plastic parts. We show how the model can be combined with chemo‐rheological measurements to guide the optimization of the process and material parameters. Although with the powders currently available, the surface appearance is inferior to the one obtained with IMC, this process shows potential.     

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.     

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.     

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.     

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.     

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.     

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.     

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.     

An economical way of using carbon fibers in sheet molding compound compression molding for automotive applications

The automotive industry is extremely cost sensitive. This is one of the main reasons why sheet molding compound (SMC) compression molding is the most popular fiber‐reinforced polymeric composites manufacturing method in this industry. SMC compression molding economics are better suited for the automotive industry than processes such as resin transfer molding or any of its variations. For automotive SMC molders to take advantage of the added stiffness provided by carbon fibers, as an alternative to the widely used glass fibers, the manufacturing process needs to be simplified as much as possible. In actual manufacturing of SMC it is not easy to combine glass fibers with carbon fibers; it will be a lot more convenient to combine SMC plies only with carbon fibers together with SMC plies with only glass fibers. This will also allow molders that will normally use only glass fibers‐based SMC to secure carbon fiber SMC from a separate supplier and use it only where it makes economic sense. The main purpose of this study is to investigate the relative improvement in physical properties that can be achieved by substituting glass fibers by carbon fibers in a per ply basis. POLYM. COMPOS. 27:718–722, 2006. © 2006 Society of Plastics Engineers     

Direct determination of the orientation of short glass fibers in an injection-molded poly(ethylene terephthalate) system

A simple and new technique for direct determination of the short fibers orientation in polymer composites is described. It is based on the fact that the shape of the fibers' cross section in the plane perpendicular to the desired direction (e.g., orientation direction) depends on the orientation angle ϕ with respect to this direction. For an eliptical shape with minor and major radii r and R, the cosϕ = r/R. Using micrographs from the polished samples' cross section and assuming a planar fiber distribution, it is possible to calculate for a part or entire cross section area: (i) the ϕ-values; (ii) the orientation parameter f_p; (iii) the angular distribution (by histograms); and (iv) the number and the sizes of the layers with more uniform fiber orientation as well as the transition zones between them. It is demonstrated for commercial poly(ethylene terephthalate) (PET) reinforced with 45 percent (by weight) short E-glass fibers (Rynite®) that each surface layer (A) takes ca. 3/16 of the sample thickness (b), the core (C)—3/16b and the boundary (B) between them occupies 3/16b. These layers are characterized, respectively, by <ϕ>_A = 28°, <ϕ>_B = 38°, <ϕ>_C = 64°, and f = 0.51, f = 0.18, f = −0.15. For the entire thickness (A + B + C) the <ϕ>_A+B+C = 44° and f = 0.17. The method described is applicable to any kind of fiber-reinforced composites from which it is possible to obtain micrographs of a desired cross section. The thickness of the cross section studied, as well as the number of the layers, does not affect the efficiency of the method.     

Monitoring cure in sheet molding compound processing

During the sheet molding compound (SMC) compression molding process, a premeasured polymer charge is placed between the heated halves of a mold which are then brought together to squeeze the polymer and fill the mold, after which pressure is maintained while the part cures. The cure stage constitutes the larger part of the molding cycle and thus affords the largest potential for cycle time reduction. In general, cure times in SMC processing are set longer than necessary, since the inherent material and process variation make it difficult to predict cure times with more than 10 to 20% accuracy. Accurate methods to detect the end of cure would be very beneficial and would permit opening the mold as soon as the material has cured, avoiding unnecessary waste of time. In this paper, several techniques that show promise for monitoring the state of cure are reviewed and experimental results given. Their relative advantages and accuracies are compared. In particular, the use of linear variable displacement transducers, pressure transducers, and thermocouples is discussed. We also show how the measurements compare to theoretical predictions of the state of cure.     

Recent developments in sheet molding compound technology

The molding of fiber-reinforced thermoset components is a complex process involving a highly exothermic chemical reaction, which takes place in the presence of flow and thermal gradients. The flow in turn is complicated by time- and temperature-dependent rheological characteristics. The industry has grown largely on the basis of empirical developments. However, numerous problems do remain which require increased understanding for solution. This report reviews work underway in numerous laboratories to characterize the flow and cure of sheet molding compounds and phenomena associated with these processes such as orientation, mechanical properties, residual internal stresses, mold fill, and surface defects.     

Temperature increase of sheet molding compound (SMC-R65) in flexural fatigue test

The temperature increase in flexural fatigue testing of sheet-molding compound SMC-R65 is investigated within a range of testing frequencies from 1000 cpm to 2200 cpm. Variation of the testing frequency affects the temperature increase and, based on 10 percent reduction in flexural stiffness, the effect of changing frequency on the fatigue lives was not detected. Steady-state temperatures are obtained in the case of specimens tested in air. A temperature analysis is carried out that gives reasonable agreement with experimental values.