Rheological characterisation and modelling of a glass mat reinforced thermoplastic for the simulation of compression moulding

authored by: P. Althaus
Abstract: The use of hybrid components in the automotive industry is steadily increasing due to their lightweight potential. By combining fibre-reinforced plastics with metallic materials, high-strength components with lower weight than monolithic metal parts can be realised. The overall aim of the project “HyFiVe” is to exploit this potential for electric vehicles by developing a scaled battery housing structure made of a glass mat reinforced thermoplastic (GMT) paired with unidirectional reinforced (UD) tapes and a metallic reinforcement frame. The GMT is formed by compression moulding and serves as the base of the battery housing structure. Numerical simulation is an efficient tool for process design that can determine a suitable process window and reduce experimental trial-and-error tests. Particularly, realistic modelling of the GMT flow behaviour is essential for reliable simulation results. In this contribution, the rheological properties of a GMT consisting of a polyamide 6 (PA6) matrix with 30% glass fibre reinforcement were determined. Isothermal compression tests were carried out with a parallel plate rheometer at different temperatures and varying squeeze rates. The squeeze force and punch displacement were evaluated to determine the rheological data of the GMT. Two methods for the modeling of the flow behaviour were considered. At first, pure shear flow was assumed and the viscosity was modelled as a function of the shear rate by means of a power-law. Secondly, a pure biaxial extension was assumed and the true stress was modelled in dependence of true strain and strain rate. Subsequently, for a verification of the material models, the compression tests were simulated in ABAQUS using the Coupled Eulerian-Lagrange (CEL) approach and the results were compared to the experiments.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference contribution
Pages: 411-421
No. of pages: 11
Publication date: 25.05.2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all)
Electronic version(s): https://doi.org/10.21741/9781644903131-46 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{af1585e8535c4c1b825073f311c28746,
title = "Rheological characterisation and modelling of a glass mat reinforced thermoplastic for the simulation of compression moulding",
abstract = "The use of hybrid components in the automotive industry is steadily increasing due to their lightweight potential. By combining fibre-reinforced plastics with metallic materials, high-strength components with lower weight than monolithic metal parts can be realised. The overall aim of the project “HyFiVe” is to exploit this potential for electric vehicles by developing a scaled battery housing structure made of a glass mat reinforced thermoplastic (GMT) paired with unidirectional reinforced (UD) tapes and a metallic reinforcement frame. The GMT is formed by compression moulding and serves as the base of the battery housing structure. Numerical simulation is an efficient tool for process design that can determine a suitable process window and reduce experimental trial-and-error tests. Particularly, realistic modelling of the GMT flow behaviour is essential for reliable simulation results. In this contribution, the rheological properties of a GMT consisting of a polyamide 6 (PA6) matrix with 30% glass fibre reinforcement were determined. Isothermal compression tests were carried out with a parallel plate rheometer at different temperatures and varying squeeze rates. The squeeze force and punch displacement were evaluated to determine the rheological data of the GMT. Two methods for the modeling of the flow behaviour were considered. At first, pure shear flow was assumed and the viscosity was modelled as a function of the shear rate by means of a power-law. Secondly, a pure biaxial extension was assumed and the true stress was modelled in dependence of true strain and strain rate. Subsequently, for a verification of the material models, the compression tests were simulated in ABAQUS using the Coupled Eulerian-Lagrange (CEL) approach and the results were compared to the experiments.",
keywords = "Glass Mat Reinforced Thermoplastic, Material Characterisation, Squeeze Flow",
author = "P. Althaus",
note = "Publisher Copyright: {\textcopyright} 2024, Association of American Publishers. All rights reserved.",
year = "2024",
month = may,
day = "25",
doi = "10.21741/9781644903131-46",
language = "English",
isbn = "9781644903131",
series = "Materials Research Proceedings",
pages = "411--421",
editor = "Araujo, {Anna Carla} and Arthur Cantarel and France Chabert and Adrian Korycki and Philippe Olivier and Fabrice Schmidt",
booktitle = "Material Forming",
}