Simulating Compression Molding for Complex Composite Components

Compression molding allows complex composite components to be produced at a rapid rate. To this end, the Moldex3D supports numerous discontinuous FRP materials that are typically used in compression molding processes. The FRP materials most commonly used in compression molding are the thermoplastics materials GMT, LFT-G, and LFT-D. Moldex3D supports thermoset type materials such as SMC and BMC.

Challenges

  • Proper amount of material
  • An ability to predict the required force to determine whether the shot attains the proper shape
  • Provide appropriate compression parameters to assure quality compression effects
  • Design the heating or cooling mold following compression of the material into the mold
  • Detect potential flash concerns
  • Achieve product consistency control

Functions of the Moldex3D

  • Simulates the filling process with single or multiple charge design
  • Visually displays various mold properties, of which can include, but are not limited to:
    • Pressure distribution
    • Volume shrinkage
    • Residual stress
    • Fiber orientation distribution
  • Predicts potential molding defects such as:
    • Bleeding
    • Flashing
  • Optimizes molding conditions such as:
    • Compression speed
    • Force
    • Mold temperature
  • Supports fiber orientation analysis procedures
  • Supports parallel processing to speed up the simulation
  • Supports the molding simulation of single or multiple charge designs
  • Fulfills a more accurate prediction of large deformation that may occur during compression molding processes
  • Supports LS-Dyna (R15.0 and newer versions)
    • Allows users to easily import initial temperatures calculated by LS-Dyna in initial charge deformation processes for the following compression molding analysis

Key Product Features of the Moldex3D

  • Supports LS-Dyna material card
    • Allows for the prediction of large deformations with the EFG method
  • Allows users to import initial temperature that has been calculated by LS-Dyna
  • Allows users to define fiber orientation of initial charge

Simulating Compression Molding for Complex Composite Components

One-Charge Design
Two-Charge Design

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