JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 65

New calculation concept shortens the design process of injection-moulded parts

Fig. 2: Validation simulations show the potential of the newly developed
method and its potential applications. Optimized anisotropic approaches and
simplified phenomenological models enable a much more precise prediction of
actual component behaviour © Fraunhofer LBF

New injection moulding tool for fibre orientation studies
Unlike fully integrative approaches, the new calculation method
does not determine the fibre orientation based on finite elements
but rather on shaped elements or key areas. These can be, for example, ribs, domes or flat areas.
A new injection moulding tool was developed to assess fibre orientation as a function of the shaped element and the angle of incidence. This offers the possibility of integrating different functional
elements while maintaining the same moulding base.
Large and small domes and ribs were used as interchangeable inserts for functional elements.
With the new tool, it is possible to investigate the influence of the
flow conditions by varying the angle of incidence. Thanks to the
concept, further approaches can be developed in a cost-effective
manner. The tool has two cavities with different wall thicknesses
that can be operated independently of each other. The base of the
moulded parts is a 60 x 60 mm plate.

A large spectrum of fibre orientations
In their experimental fibre orientation analyses, the Fraunhofer
LBF scientists found a variety of distinct fibre orientations. The information necessary for the desired modelling method is derived
from the second-order orientation tensor, i.e. its main orientation
and degree of distribution. The information obtained can now be
used to determine the anisotropy and the main direction for each
layer. In this case, the number of layers can be defined as a change in
the orientation distribution (suitable for the material) or as a manual specification (based on experience). An automatic analysis algorithm determines a suitable material model, for example isotropic
or orthotropic, for each layer identified, as well as all the necessary
model parameters. For this purpose, in addition to the data from
the computer, determined mechanical test data are required as an
input. This information can then be transferred to the model in the
structure simulation (mapping). The method can be applied to results from injection simulations as well as to results of computed
tomography (CT) analyses.
In addition to a simplified design strategy, further application scenarios are created using an information database depending on the
shaped elements. On the one hand, the information can be used
to design components in accordance with the potential stress they
will be exposed to; for example, ribs in the correct positions with
the optimum shape and orientation. On the other hand, it has been
shown that the results can be used to optimize the fibre orientation
calculation used in integrative approaches.
The results presented here were generated as part of the IGF project 18362N "Phenomenological Calculation Strategy for Short fibre-reinforced Injection Moldings", funded by the German Federal
Ministry for Economic Affairs and Energy via the AiF as part of the
programme for the promotion of industrial joint research and development (IGF) following a ruling of the German Bundestag.
More information:
www.lbf.fraunhofer.de

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JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019

Cover
Edito
Moving composites forward: on the shoulders of giant
Contents
NEWS
In brief
Successful partners
Agenda
BUSINESS
Matrix - CFRP composite manufacturing trends
Cost - A brand-new approach for economically competitive composites
MANUFACTURING
Fibre placement - Replacing individual unit tests by integrated process control
NDT - Optical metrology improves the production of composite products at every step
Initiative - Spotlights from the world of lightweighting
FEATURE SPORTS & LEISURE - The largest testing ground
Success story - DPS designs the world’s most advanced skis
Carbon - New type of unidirectional prepreg for sport applications with complex shapes
Additive manufacturing - lnnovative composite bicycle frame
Textile - Porcher lndustries: excellence in sports and leisure
Innovations - Sports on the scene at JEC World 2019
Carbon - The next generation of high-performance rigging
Standardisation - Research, innovation and development for composite marine and offshore applications
SOLUTIONS
Infrastructure - Can carbon-reinforced concrete replace steel in the long run?
Art - “Train your brain, think disruptive, outside the box and follow your visions!”
Music - Music instruments from carbon, glass or flax fibres
Watch - A watch ahead of its time
In the world - Composites visit the doctor
TECHNOLOGY
Ageing - Effects of ageing on the mechanical and structural properties of glass/epoxy composite pipes in seawater
Inside the lab - Advanced Composites Research Group – Queen’s University Belfast
Index
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JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 68
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Cover
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 2
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Edito
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Moving composites forward: on the shoulders of giant
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 5
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Contents
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 7
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - In brief
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 9
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Successful partners
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Agenda
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Matrix - CFRP composite manufacturing trends
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 13
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 14
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Cost - A brand-new approach for economically competitive composites
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 16
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 17
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 18
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Fibre placement - Replacing individual unit tests by integrated process control
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 20
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - NDT - Optical metrology improves the production of composite products at every step
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 22
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 23
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Initiative - Spotlights from the world of lightweighting
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 25
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 26
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Success story - DPS designs the world’s most advanced skis
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 28
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Carbon - New type of unidirectional prepreg for sport applications with complex shapes
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 30
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Additive manufacturing - lnnovative composite bicycle frame
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 32
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Textile - Porcher lndustries: excellence in sports and leisure
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 34
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 35
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Innovations - Sports on the scene at JEC World 2019
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 37
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Carbon - The next generation of high-performance rigging
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 39
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Standardisation - Research, innovation and development for composite marine and offshore applications
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 41
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 42
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Infrastructure - Can carbon-reinforced concrete replace steel in the long run?
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 44
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 45
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 46
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Art - “Train your brain, think disruptive, outside the box and follow your visions!”
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 48
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Music - Music instruments from carbon, glass or flax fibres
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 50
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 51
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Watch - A watch ahead of its time
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 53
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - In the world - Composites visit the doctor
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 55
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Ageing - Effects of ageing on the mechanical and structural properties of glass/epoxy composite pipes in seawater
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 57
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 58
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 59
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 60
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 61
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Inside the lab - Advanced Composites Research Group – Queen’s University Belfast
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 63
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 64
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 65
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 67
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