Advanced modeling and simulation of sheet moulding compound (SMC) processes

Abstract

In SMC processes, a charge of a composite material, which typically consists of a matrix composed of an unsaturated polyester or vinylester, reinforced with chopped glass fibres or carbon fi bre bundles and fillers, is placed on the bottom half of the preheated mould. The charge usually covers 30 to 90% of the total area. The upper half of the mould is closed rapidly at a speed of about 40 mm/s. This rapid movement causes the charge to flow inside the cavity. The reinforcing fibres are carried by the resin and experience a change of confi guration during the flow. This strongly influences the mechanical properties of the final part. Several issues compromises its efficient numerical simulation, among them: (i) the modeling of flow kinematics able to induce eventual fibres/resin segregation, (ii) the con ned fibres orientation evolution and its accurate prediction, (iii) local dilution effects, (iv) flow bifurcation at junctions and its impact on the fibres orientation state, (v) charge / mould contact and (vi) parametric solutions involving non-interpolative fields. The present paper reports advanced modeling and simulation techniques for circumventing, or at least alleviating, the just referred difficulties.