Fully impregnated fiber-reinforced thermoplastic sheets, or the so-called organic sheets, allow the thermoforming of parts within very short cycle times. This article describes the development of the next generation of organic sheet materials based on recycled carbon fibers and polyamide 6 staple fiber yarns. Regardless of the recycled nature of the fibers and an average fiber length of 25 mm, the organic sheets still reach a comparable level of the tensile strength and modulus of continuous fiber-reinforced organic sheets made of virgin CF with the same reinforcement structure. Due to the staple fiber yarn architecture, the organic sheets feature a deep-drawing ability of a total plastic deformation up to 50% in the fiber direction. The effect is enabled via an interfiber sliding when the organic sheet is processed in the molten condition. The creation of a finite element model for the thermoforming process simulation of the material is also presented. Predictions of the plastic strain distribution and its magnitude are shown to agree well with forming experiments where a curved geometry is formed to different depths.

No abstract

No abstract

The compression molding of sheet molding compounds (SMCs) is typically thought of as a fluid mechanics problem. The usage of CF-SMC with high fiber volume content (over 50%) and long fiber reinforcement structures (up to 50 mm) challenges the feasibility of this point of view. In this work a user-defined material model based on a solid mechanics formulation is developed in LS-DYNA®. The material model is built on a modular principle where the different influence factors caused by the material characteristics form building blocks. The idea is that these blocks are represented by simple mathematical models and interact in a way that forms the overall behavior of the SMC material. To analyze the behavior of the SMC material and create input parameters for the material model it is necessary to perform some kind of material characterization experiment. This paper presents the press rheometry test which can be perform in two variations, differing in terms of specimen size and shape and degree of coverage in the tool. Here the material response to the compression molding can be analyzed and by the visualization of the flow front development the anisotropy and homogeneity of the material can be assessed. For a comparison between the material model and reality the two variations of the press rheometry test are simulated. The simulation results show a good prediction of the experiments. The differences between experiment and simulation can be used to further improve the model in a later process.