Computational simulation methods for molding of composite materials

Currently used methods for the numerical simulation of the molding of short-fiber-reinforced composite materials are presented. Model formulations for both dilute and non-dilute fiber suspensions are discussed. Previous studies show that for dilute fiber suspensions, the orientation formation in a geometrically complex, three-dimensional, and time dependent flow can be obtained efficiently and without approximations in the governing equations. For such systems, it is possible to decouple the principal orientation directions and the degree of alignments with respect to the principal orientation directions. Thus, one can solve for principal orientation directions without obtaining degree of alignments. The flow induced orientation field in the vicinity of an inlet gate placed near a mold wall is obtained by using dilute suspension models. Orientation results are presented at different layers through the thickness, depicting the skin-core orientation structure and mold wall effects.