Influence of flow–fiber coupling during mold-filling on the stress field in short-fiber reinforced composites

The anisotropic elastic properties of injection molded composites are fundamentally coupled to the flow of the fiber suspension during mold-filling. Regarding the modeling of mold-filling processes, both a decoupled and a flow–fiber coupled approach are possible. In the latter, the fiber-induced viscous anisotropy is considered in the computation of the flow field. This in turn influences the evolution of the fiber orientation compared to the decoupled case. This study investigates how flow–fiber coupling in mold-filling simulation affects the stress field in the solid composite under load based on the final elastic properties after fluid–solid transition. Furthermore, the effects of Newtonian and non-Newtonian polymer matrix behavior are investigated and compared. The entire process is modeled micromechanically unified based on mean-field homogenization, both for the fiber suspension and for the solid composite. Different numerical stabilization methods of the mold-filling simulation are discussed in detail. Short glass fibers with a typical aspect ratio of 20 and a volume fraction of 20% are considered, embedded in polypropylene matrix material. The results show that the flow–fiber coupling has a large effect on the fiber orientation tensor in the range of over ± 30% with respect to the decoupled simulation. As a consequence, the flow–fiber coupling affects the stress field in the solid composite under load in the range of over ±  10%. In addition, the predictions based on a non-Newtonian modeling of the matrix fluid differ significantly from the Newtonian setup and thus the necessity to consider the shear-thinning behavior is justified in a quantifiable manner.