Injection molding simulation, including prediction of fiber filler orientations, has been widely used to predict and troubleshoot mold filling and part warp. Recently, with increasing focus on automotive light-weighting to achieve carbon emission reductions, there has been an increasing need for design validation tools which consider the structural performance of the molded part under load.
For fiber filled plastics, the orientation of the fibers has a critical effect on the structural performance. Consequently, simulation tools are required which allow the structural analysis to consider the effect of fiber orientation and the nonlinear anisotropic response of the plastic.
For injection molded plastic parts that contain short fiber reinforcing fillers, prediction of the mechanical response is complicated by the fact that the elastic, plastic, and rupture responses of the composite material are highly anisotropic due to the local orientation of the reinforcing fibers [1]. These local fiber directions can vary throughout the part due to spatial variation of flow conditions during the injection molding process [2], adding further complications.
The topics that follow outline the strategy used by Autodesk to simulate the mechanical response of a fiber filled, injection molded part with Advanced Material Exchange.