Effect of fiber content and wall slip phenomenon on the polymer filling behavior in thermoset injection molding and simulation process

近年来，由于其各种优点，在工业制造环境中使用仿真过程的需求有所增加。良好的模拟结果的必要条件是正确和完整的材料数据。热固性塑料注射成型模拟中，其材料数据来源有限，很少能从模拟工具的数据库中获得。材料数据的生成需要在流变和热性能测量以及优化算法方面的广泛知识。此外，为了准确模拟热固性塑料的注塑成型过程，需要对热固性塑料的充模特性有深入的了解，为此，塑料工程系教授通过自己开发的有效而实用的方法，发现了热固性塑料和热塑性塑料完全相反的充模行为。具体地，对于热固性注射成型，在热固性熔体和壁表面之间存在强烈的滑移，这在热塑性材料的注射成型中没有发现。然而，变量，如纤维和填料的量，模具表面粗糙度和模具压力，可以影响滑移现象尚未被调查。此外，到目前为止未知的滑移现象的知识集成到仿真模型仍然缺失。因此，本研究计划主要围绕两个科学目标展开：第一，全面了解纤维增强热固性注塑材料的充模行为与影响因素之间的关系;第二个是模拟模型的发展，描述了调查的充型行为。模拟结果与实验结果的验证将显示模型的质量是否足以开发真实的热固性塑料注塑成型模拟过程，这有助于工业公司提高设计的成功率，缩短开发周期以及预测潜在的缺陷。

The demand of using simulation processes in the industrial manufacturing environment has been increased in recent years because of its various advantages. The necessary requirements for good simulation results are correct and complete material data. With thermosets injection molding simulation, its material data are found in limited sources and are seldom available from data bank of simulation tools. The generation of material data requires an extensive knowledge in measurement of rheological and thermal properties as well as optimization algorithm. In addition, to simulate exactly the thermosets injection molding compound process, it requires a profound knowledge in the mold filling characteristics of thermoset injection molding compounds.Concerning this matter the Professorship of Plastics Engineering found a completely opposite mold filling behavior of thermosets and thermoplastics by an own-developed effective and useful method. Specifically, for the thermoset injection molding, there is a strong slip between the thermoset melt and wall surface, which is not found for the injection molding of thermoplastic materials. However, the variables like amount of fiber and filler, the mold surface roughness and mold pressures that can influence the slip phenomenon has not yet been investigated. Furthermore, the integration of the knowledge about the up to now unknown slip phenomenon into the simulation models is still missing. Therefore, this research proposal focuses on two scientific key goals.The first one is to gain a complete understanding of the relationships between the influencing parameters and the mold filling behavior of fiber-reinforced thermoset injection molding compounds. The second one is the development of simulation models which describe the investigated mold filling behavior. A validation of the simulation results with experimental results will show whether the quality of the models is sufficient for the development of an authentic thermoset injection molding simulation process, which helps industrial companies to increase the success of the design, to shorten development cycles as well as to predict potential defects.