The objective of this project is to examine how changing the glass-fiber cross-section influences the manufacturability of glass-reinforced polymeric materials. Specifically, the two cross-sections that will be examined are round glass-fibers vs rectangular glass-fibers. It is well known that changing the fiber cross-section to a rectangular cross-section helps minimize part warpage. However, it is unclear if extra care needs to be taken when processing these materials to ensure fiber breakage is not substantially changed with the broader cross-section. The study can look at many aspects and be correlated to simulation models to see how molding these different cross-section fibers might influence the dimensional stability of the parts, weld line strength, fiber breakage, and changes in the filling pattern of the materials.
Sponsored By: The Madison Group
Team Members
Kaitlyn Nicholas | William Rieg | Zackery Trim | |
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Project Summary
Overview
The role of fiber cross-section shapes on composite manufacturing and performance was studied. The mechanical and rheological influence of round and rectangular glass-fiber cross-sectional shapes was examined and compared in Nylon 6. Characterization techniques were used to obtain the results for comparison by identifying the key properties and purposes of glass-fibers. The use of high glass-fiber weight percent (50 wt%) and a hygroscopic material was also taken into consideration.
Objectives
- The objective of this project was to
- Examine glass-fiber cross-section influence on manufacturability and performance of glass-reinforced Nylon 6.
- Observe cross-section fibers influence on part dimensional stability, weld line strength, fiber breakage, and changes in filling pattern.
Approach
- Researched background and theory
- Testing techniques
- Articles
- Injection molding
- 2-stage optimization process
- Capillary rheometry
- Melt viscosity
- Shear sensitivity
- Tensile testing
- Ultimate tensile strength
- Young’s modulus
- Scanning electron microscopy (SEM)
- Fiber-matrix adhesion
- Fiber breakage
- Fiber flow orientation
Outcomes
- New approaches to characterization
- The importance of glass-fiber sizing
- Flow orientations of glass-fibers
- Analysis of crystallization temperature of the composites
- Differential Scanning Calorimetry
- Molding simulation analysis
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