Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit
Lightweight structural components made from plastics play an important role in achieving decarbonization targets in technical applications. Due to cost advantages and design freedom, short-fiber-reinforced plastics processed by injection molding play a major role here. To improve sustainability, traditional fossil-based plastics are increasingly being replaced by recyclates and plastics with biological components. For reliable component design using structural simulations, the mechanical properties must be known and adequately represented in the simulation model. The static and cyclic dynamic behavior of injection-molded components, and thus their load-bearing capacity and service life, depends on fiber volume content, as well as the fiber orientation and length distribution, which are influenced by the manufacturing process. Thus, for an efficient component design, the corresponding anisotropic mechanical properties must be considered. This contribution presents the results of mechanical tests on petrochemical-based glass fiber-reinforced plastics (PA6-GF30) and bio-based alternatives (PA610-GF40). Furthermore, the process of material modeling for the structural simulation using ANSYS is discussed, including the mapping of the fiber orientation results from upstream process simulations. Adjusted material models are introduced, to optimize the simulative representation of the experimental test data. Finally, the results of the structural simulation at sample level are presented and discussed. On this basis, the article provides relevant insights on the representation of the described plastic materials in structural mechanics simulation with Ansys.
Abstract
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