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1

Study of the fracture facies when drilling c-orthocryl carbon-resin composite material for orthopedic prosthesis

Mesrafet F., Menail Y., Chaoui K., Bouhafara D.

International Journal of Applied Mechanics and Engineering

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2026

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Vol. 31, no. 1

75--91

EN

The objective of this study is to determine the different micro damages caused to the socket of an orthopedic prosthesis, during its drilling before and after static tensile test, in order to estimate the ultimate microscopic damage when drilling. For this, carbon-c-orthocryl composite material specimens were produced by infusion moulding, a mechanical test is carried static traction and charpy impact, to determine their mechanical performance. To quantify and compare the different damages caused by machining, SEM microscopy was carried out through deferent surfaces. The results Visualize that the material has undergone all the known Degradations including resin breakage, intralaminar, translaminar, and interlaminar delamination, decohesion, and fiber ruptures are consistent with those referenced in the bibliography., All these degradations were identified and quantified to determine their origins. Poor wetting between the fibers and the resin was identified, to address this, it was recommended to review the moulding technique by increasing the amount of retarder. Furthermore, the contribution of this study yield essential insights into the structural laminate and the resin composition, providing a pathway for enhancing carbon-c-orthocryl socket machinability to drilling.

2

Effect of polymer microspheres on selected properties of injection-molded shapes based on thermoplastic starch

Jeziórska Regina, Tor-Świątek Aneta, Szadkowska Agnieszka, Klepka Tomasz, Borkowski Mateusz, Skrzypczyńska Katarzyna

Polimery

|

2025

|

Vol. 70, nr 11-12

783--792

EN

Microporous products were obtained by injection molding. The effect of adding 1-5 wt% of a foaming agent (Expancel® FG92 MB 120) on selected properties of TPS/PBAT blend compatibilized with maleic anhydride-grafted PLA (MPLA) was investigated. The addition of a foaming agent did not significantly affect the wetting properties or the energetic character of the surface. SEM analysis showed that, unlike blow molding, injection molding, due to the high flow rate, high pressure, and rapid cooling, leads to the formation of closed but deformed pores. Significant structural variability and increased surface roughness occur along the flow direction, which is not fully correlated with internal porosity. This structure results in only minor changes in mechanical properties compared to the solid material. Density, hardness, tensile strength and elongation at break gradually decrease and moisture absorption increases with increasing foaming agent content.

PL

Mikroporowate wyroby otrzymano metodą formowania wtryskowego. Zbadano wpływ zawartości środka spieniającego (Expancel® FG92 MB 120), stosowanego w ilości 1, 3 i 5% mas., na wybrane właściwości mieszaniny TPS/PBAT kompatybilizowanej PLA szczepionym bezwodnikiem maleinowym (MPLA). Dodatek środka spieniającego nie wpłynął znacząco na właściwości zwilżające ani na charakter energetyczny powierzchni. Analiza SEM wykazała, że w przeciwieństwie do formowania z rozdmuchem, formowanie wtryskowe, ze względu na dużą szybkość przepływu, wysokie ciśnienie i szybkie chłodzenie, prowadzi do tworzenia się zamkniętych, ale zdeformowanych porów. Wzdłuż kierunku przepływu występuje duża zmienność struktury i większa chropowatość powierzchni, która nie jest w pełni skorelowana z porowatością wewnątrz materiału. Taka struktura powoduje jedynie niewielkie zmiany właściwości mechanicznych w stosunku do materiału litego. Gęstość, twardość, wytrzymałość na rozciąganie i wydłużenie przy zerwaniu stopniowo zmniejszają się, a chłonność wilgoci zwiększa wraz ze wzrostem zawartości środka spieniającego.

3

Thermoplastic injection molding process simulations and their experimental verification

Nabiałek Jacek, Kwiatkowski Dariusz

Journal of Applied Mathematics and Computational Mechanics

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2025

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Vol. 24, nr 3

98--107

EN

The simulation of the thermoplastic injection process was carried out using the Autodesk Simulation Moldflow Insight software. The seven-parameter Cross-WLF rheological model was adopted for the tests. Knowledge of the pvT relationship is essential for simulating the pressing phase and for determining the residual stresses and deformation of the molded parts. For this purpose, the Tait equation was used in the numerical analysis. In the initial stage of the simulation, a solid model of the molded part was created using the Siemens NX software. In the subsequent step, the molded part model was imported, and the FEM mesh was applied. Then, the injection process parameters were entered into the program. This data included thermal, rheological, and mechanical properties of the injected thermoplastic. The recorded video sequences were compared with the results of numerical simulations, and the extent to which computer modeling of the injection process can be useful in practice was assessed.

4

The differential scanning calorimetry investigations of polymer blends of polypropylene and polyamide 6 with the addition of polyvinylpyrrolidone

Gnatowski Adam, Palutkiewicz Paweł

Archives of Engineering Knowledge

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2025

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T. 11, Nr 1

1--5

EN

Polymer blends (mixtures), which are a combination of two or more materials with different properties, are widely used in many industries. By combining different polymers, materials with new physical, thermal and chemical properties are obtained. The work investigated immiscible polymer mixtures (polypropylene (PP) with the trade name Malen P J-400 by Basell Orlen and polyamide 6 (PA6) Tarnamid T-27 MS by Grupa Azoty) with the addition of a compatibilizer - polyvinylpyrrolidone (PVP). The test samples, in the form of dog-bone shaped parts for a static tensile test, compliant with the PN-EN ISO527-2:1998 standard, were manufactured by injection moulding. Different injection parameters were used for the mixtures (injection temperature and cooling time in the mould). The degree of crystallinity and melting temperature were determined using the DSC (Differential Scanning Calorimetry) method. Significant differences in the degree of crystallinity and smaller differences in the melting point values were demonstrated.

5

Work safety during the injection molding process of polymer materials

Caban Renata, Dudek Agata, Pietraszek Jacek

System Safety : Human - Technical Facility - Environment

|

2024

|

Vol. 6, iss. 1

320--329

EN

Injection molding is one of the fundamental processes used in the processing of widely utilized engineering materials, such as polymer materials. The injection molding method is commonly employed in the processing of both thermoplastic and thermosetting polymers. Despite the various technical measures implemented by manufacturers to mitigate risks to operators and the environment, injection molding machines still present potential hazards that could lead to accidents. This paper will describe the hazards associated with operating injection molding machines, as well as the preventive measures used by designers and those involved in the injection molding process. In the context of material modification, particularly polymer materials, injection molding plays a crucial role not only in shaping components but also in modifying the material properties. The ability to modify polymers during the injection molding process, such as through the inclusion of additives or reinforcements, allows for the creation of materials with enhanced mechanical properties, thermal resistance, or other desired characteristics. The safe and efficient execution of these processes requires a thorough understanding of both the material behavior and the potential operational hazards associated with the molding machines. This paper will also touch on how these material modifications impact the safety protocols and preventive measures in place to ensure smooth operation.

6

Innovative polymer composites based on biomedical materials - Rapid communication

Bulanda Katarzyna, Bartusik-Aebisher Dorota, Oleksy Małgorzata, Aebisher David

Polimery

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2024

|

Vol. 69, nr 5

318--324

EN

The article presents preliminary research on the influence of calcium phosphate (10–40 wt%) on the functional properties of ABS. Maleic anhydride grafted polyethylene was used as a compatibilizer (0.5 wt%). The mass flow rate, tensile properties and hardness were determined. The effect of the filler on the color change of the polymer matrix was also examined. For a composite containing 20 wt% calcium phosphate, the mechanical properties of samples obtained by 3D printing and injection molding were compared, with worse properties obtained by 3D printing. This can be explained by limited adhesion between the printed layers.

PL

W artykule przedstawiono wstępne badania wpływu fosforanu wapnia (10–40% mas.) na właściwości użytkowe ABS. Jako kompatybilizator użyto polietylen szczepiony bezwodnikiem maleinowym (0,5% mas.). Określono masowy wskaźnik szybkości płynięcia, właściwości mechaniczne przy rozciąganiu i twardość. Zbadano także wpływ napełniacza na zmianę barwy osnowy polimerowej. Dla kompozytu zawierającego 20 wt% fosforanu wapnia porównano właściwości mechaniczne próbek uzyskanych metodą druku 3D i formowania wtryskowego, przy czym gorsze właściwości uzyskano metodą druku 3D. Można to wyjaśnić ograniczoną przyczepnością pomiędzy drukowanymi warstwami.

7

Mechanical properties of ABS samples manufactured under different process conditions

Czyżewski Piotr, Marciniak Dawid, Sykutera Dariusz

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2024

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Vol. 72, nr 1

art. no. e147065

EN

The purpose of this study is to determine the effect of manufacturing conditions on the mechanical properties and structure of ABS parts. Two sets of samples with the same geometric characteristics were produced by fused deposition modelling (FDM) and injection molding (IM). The molding pressure and cooling rate were found to have a significant effect on shaping the mechanical properties and structure of ABS products. The manufacturing method and adopted process parameters have a significant impact on the degree of packing of macromolecules in the volume of the product and thus determine its density. Selected mechanical properties were determined and compared with their specific gravity. The research was carried out using tools and machines, i.e. injection molds of unique design and standard measuring stations. Tensile and bending strengths and Young’s modulus were related to the density of products obtained under different process conditions and having gradient and solid structures. The results provide useful information for engineers designing products using FDM technology. Relating tensile and flexural strength and Young’s modulus to the specific gravity of the product. It was found that the value of product properties is closely related to various process conditions, which further provides a true description of the products.

8

Recycling waste polypropylene to produce new composite materials with jute reinforcements

Hoque Mohammad Amirul, Sultana Shahin, Sarker Md. Khabir Uddin, Islam Zahidul

Advances in Materials Science

|

2023

|

Vol. 23, nr 3(77)

21--32

EN

Waste polypropylene (PP) polymer was collected, washed, dried and mechanically recycled into granules. Natural fibers are a sustainable and renewable resource, and in this work, Corchorus olitorius jute fiber was used as a reinforcing agent with waste PP. Jute fiber was collected from local market, cleaned, dried and cut into 1-2 mm in length for the production of waste PP-jute composites. The molecular structure of waste PP and virgin PP were characterized by the attenuated total reflection-fourier transform infrared (ATR-FTIR). The purpose of the current research was to examine the effectiveness of waste PP by comparing waste PP-jute composites and virgin PP-jute composites. The injection molding process was utilized to make jute fiber reinforced waste PP composites with various jute fiber loadings (5%, 10%, 15%, 20%, 25%, and 30% in weight).The same process was used to produce virgin PP composites reinforced with jute fiber. All composites undergo water absorption and tensile testing in order to assess the recycled PP. Injection molded virgin and waste PP's physico-mechanical, thermal, and tensile strengths are also examined. In comparison to waste PP, virgin PP has a 6% greater tensile strength and a 19% higher elongation at break. Results from waste PP-jute composites and virgin PP-jute composites did not significantly differ from one another. Products made from recycled PP can thus be both economically and environmentally viable.

9

Geometrical accuracy of injection-molded composite gears

Zajdel Magdalena, Pisula Jadwiga, Sobolewski Bartłomiej, Sanocki Tadeusz, Majcherczyk Henryk, Budzik Grzegorz, Oleksy Mariusz

Polimery

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2022

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Vol. 67, nr 7-8

324--336

EN

The geometrical accuracy of injection-molded gears made of PA6, PA66 and PPA filled with glass fiber (30, 35 and 50%) were investigated. Using the AMI software, the injection mold cavity and the injection point distribution were simulated and the orientation of the glass fibers in the product was determined. The low accuracy class of injection-molded gears may indicate the need to optimize the injection process, which will be the subject of further research.

PL

Zbadano dokładność geometryczną formowanych wtryskowo kół zębatych wykonanych z PA6, PA66 i PPA napełnionych włóknem szklanym (30, 35 i 50%). Za pomocą oprogramowania AMI przeprowadzono symulację gniazda formy wtryskowej i rozmieszczenia punktu wtrysku oraz określono orientację włókna szklanego w wyrobie. Niska klasa dokładności formowanych wtryskowo kół zębatych może wskazywać na konieczność optymalizacji procesu wtryskiwania, co będzie przedmiotem dalszych badań.

10

Effect of injection parameters on tensile and flexural properties of green composites

Rathore Rajat, Bhattacharjee Saugata, Bora Prayas, Rao Gorrepotu Surya, Samanta Sutanu, Debnath Kishore

Composites Theory and Practice

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2022

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R. 22, nr 4

196--204

EN

Natural fibres are used to develop green composites due to their environmentally friendly nature, ease of availability, low cost, higher strength, as well as good thermal, acoustic, and insulating properties. In this study, jute fibre (JF) and sisal fibre (SF) were considered as reinforcement and a biodegradable polymer, namely polylactic acid (PLA), was selected to fabricate the composites by the injection moulding process. The fibres were chemically treated with sodium hydroxide (NaOH) at a concentration of 2% to improve the characteristics of the fibre. The effect of the injection moulding parameters like injection pressure (bars), injection speed (mm/s), and melting temperature (°C) on the tensile and flexural properties of the sisal fibre/polylactic acid (SF/PLA) and jute fibre/polylactic acid (JF/PLA) composites were investigated. Taguchi’s L9 orthogonal array was chosen for the design of experiments, and analysis of variance (ANOVA) was performed to find the significance and contribution of the selected parameters. The optimum levels from the main plots of both the tensile and flexural strength of the JF/PLA composite were found to be the injection pressure of 90 bars, injection speed of 60 mm/s, and injection temperature of 165°C. Meanwhile, the optimum level of tensile strength for SF/PLA-based composite was recorded as the injection pressure of 70 bars, injection speed of 40 mm/s, and temperature of 165°C. For the flexural strength, the optimum level was determined as the injection pressure of 90 bars, injection speed of 60 mm/s, and temperature of 165°C.

11

Wady formowania wtryskowego. Jak im zapobiegać?

Dyrda Jan

Świat Obrabiarek i Narzędzi

|

2021

|

R. 16, nr 4

20--21

12

Design of the Optimal Geometry of the Moulded Piece Based on Numerical Analyses in Cadmould 3D-F

Mańko Paweł Piotr, Majewski Łukasz

Advances in Science and Technology. Research Journal

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2020

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Vol. 14, no. 1

96--106

EN

The subject of the work was the assessment of the possibility of using Cadmould 3D-F® software based on numerical analysis to design complex injection moulding cavities with plasticised polymer feed channels on the example of an element requiring special dimensional accuracy. The overarching goal of the design process was to create the most advantageous geometry of the injection moulding cavity model and the dedicated material supply channels, which will minimize the effect of problems occurring during injection moulding process, such as processing shrinkage, surface collapse, warpage and mouldings deformation. As an additional criterion, the smallest possible degree of complexity of the designed system was adopted for economical reasons and elimination of subsequent production problems resulting from the complex geometry of the designed mould.

13

Ocena wpływu wyboru modelu mikromechanicznego na prognozowanie orientacji włókien oraz właściwości mechaniczne kompozytu WPC

Frącz Wiesław, Janowski Grzegorz

Zeszyty Naukowe Politechniki Rzeszowskiej. Mechanika

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2019

|

z. 91 [299], nr 1-2

5--16

PL

W pracy oceniono efektywność zastosowania modeli mikromechanicznych Folgara-Tuckera oraz RSC w prognozowaniu powtryskowej orientacji włókien w matrycy polimerowej dla specyficznego kompozytu WPC złożonego z matrycy polimerowej PP oraz napełniacza, tj. włókien drzewnych w ilości 15% mas. Obliczone wartości składowych tensora orientacji włókien w matrycy polimerowej pozwoliły również na ocenę wpływu zastosowanych modeli mikromechanicznych na możliwości prognozowania właściwości mechanicznych kompozytu WPC z zastosowaniem modelu homogenizacji Mori-Tanaka. Należy zauważyć, że domyślnym modelem mikromechanicznym stosowanym w wielu programach CAE specjalizowanych w zakresie procesu formowania wtryskowego jest model Folgara-Tuckera. Istotna staje się więc ocena przydatności modelu RSC, który nie jest modelem domyślnym i próba odpowiedzi, czy można go stosować w prognozowaniu właściwości przetwórczych i mechanicznych kompozytów WPC.

EN

This article evaluates the effectiveness of selected micromechanical models, such as Folgar-Tucker and RSC, in numerical calculations concerning fiber orientation prediction in a polymer matrix for the WPC composite containing 15% by mass of wood fibers. In addition, the obtained values of fiber orientation tensor in the polymer matrix allowed to assess the influence of the applied micromechanical models on the possibilities of predicting the mechanical properties of the WPC composite using the Mori-Tanaka homogenization model. It should be noted that the default micromechanical model suggested in CAE software including the injection moulding process modules is the Folgar-Tucker model. Hence, it is important to investigate whether the second optional model, i.e. RSC, should be the main model used in predicting the processing and mechanical properties of WPC composites.

14

Wspieranie zrównoważonej przedsiębiorczości w formowaniu wtryskowym części z tworzyw sztucznych poprzez optymalizację zużycia materiału

Zgodavová Kristína, Bober Peter, Sütöová Andrea, Lengyelová Kristína

Przemysł Chemiczny

|

2019

|

T. 98, nr 3

399--408

PL

Przedstawiono możliwości ograniczenia zużycia tworzyw sztucznych podczas formowania wtryskowego w przedsiębiorstwie, które dostarcza komponenty dla przemysłu motoryzacyjnego, w zakresie zrównoważonej przedsiębiorczości. Przedmiot badań stanowiły wymiary, masa oraz cechy wizualne, czyli parametry istotne dla jakości, CTQ (critical to quality), związane z formowaniem wtryskowym elementów z tworzyw sztucznych i ich wskaźniki zrównoważenia SUI (sustainability indicators). Parametry CTQ badano za pomocą narzędzi LSS (lean six sigma), metodą SPAN (systematic procedure for attaining necessary capability). Opisano parametry SUI polipropylenowych części deski rozdzielczej samochodu. W początkowej konfiguracji parametrów, a następnie ich odpowiedniej kombinacji w planowaniu doświadczeń DoE (design of experiments), masa części została zmniejszona, a parametry SUI uległy poprawie. Oryginalność tych badań polegała na stworzeniu i praktycznym uzasadnieniu wybranej metodologii dzięki połączeniu powszechnie znanych narzędzi LSS ze starszą i mniej znaną metodą SPAN, a także na osiągnięciu zrównoważenia produktu już na etapie projektowania komponentów.

EN

Process for prodn. of automotive parts by injection molding of polypropylene was optimized (stretch size, clamping force, and clamping time) to reduce the material consumption. As result of the optimization, the mass of an individual part was decreased by about 2% without any deterioration of its quality characteristics, dimensions or appearance.

15

Modelowanie procesu formowania wtryskowego koła zębatego

Kołtało Kamil, Kozioł Mateusz

Przegląd Mechaniczny

|

2019

|

nr 1

38--40

PL

Przedmiotem pracy jest modelowanie procesu formowania wtryskowego koła zębatego z tworzywa termoplastycznego. W tym celu zastosowano program SOLIDWORKS do utworzenia modelu CAD wypraski i program AUTODESK MOLDFLOW do przeprowadzenia symulacji komputerowych procesu wtryskiwania wypraski oraz analiz przebiegu procesu i jego wyników. Doboru materiału użytego w badaniach dokonano w programie CAMPUS. Wykonano symulację wtrysku, uwzględniając położenie punktu wtrysku oraz różne parametry procesu. Wyniki analiz numerycznych procesu wytwarzania koła zębatego umożliwiły uzyskanie odpowiedniej jakości wypraski oraz zoptymalizowane parametry przetwórstwa.

EN

The subject of this work is the modeling of the process of forming an injection gear made of thermoplastic. For this purpose, the SOLIDWORKS software was used to create a CAD model of the molded piece and the AUTODESK MOLDFLOW software to carry out computer simulations of the injection molding process and analysis of the process and its results. Injection simulation was performed taking into account the location of the injection point and various process parameters. The results of numerical analyzes of the gear manufacturing process made it possible to obtain an appropriate, quality molding and optimized processing parameters.

16

Analiza wpływu struktury geometrycznej powierzchni gniazda formy wykonanej w technologii PolyJet na stan powierzchni wypraski

Budzik Grzegorz, Turek Paweł, Dziubek Tomasz, Żelechowski Damian

Przegląd Mechaniczny

|

2019

|

nr 6

27--30

PL

W przypadku produkcji wielkoseryjnej, w technologii formowania wtryskowego najczęściej stosowane są formy stalowe bądź ze stopów aluminium, jednakże stosowanie ich do produkcji jednostkowej, ze względu na kosztowny proces kształtowania, jest mało opłacalne. Wykorzystanie fotopolimerowych form wtryskowych wytwarzanych w technologii PolyJet firmy Stratasys do produkcji jednostkowej niesie ze sobą korzyści związane z obniżeniem kosztów oraz czasu produkcyjnego. Jednym z parametrów określających ich przydatność w procesie produkcyjnym jest struktura geometryczna powierzchni. W pracy przedstawiono wyniki pomiarów chropowatości gniazda formującego wykonanego w technologii PolyJet oraz wypraski uzyskanej dzięki niej. Otrzymane wartości przedstawiono w formie graficznej oraz zestawiono w tabeli, a po przeprowadzonej analizie skonstruowano wnioski.

EN

In the case of high volume production in injection molding technology, steel molds or aluminum alloys are most often used, however, their use for unit production, due to the costly process of shaping them, is not very profitable. The use of photopolymer injection molds manufactured in PolyJet technology by Stratasys in unit production brings benefits related to the reduction of costs and production time. One of the parameters determining their usefulness in the production process is the geometric structure of the surface. The paper presents the results of roughness measurements of a cavity in printed injection mold with PolyJet technology and molding obtained thanks to it. The obtained values are presented in graphical form and summarized in the table, and after the analysis, conclusions were constructed.

17

The effect of changing injection temperature on some mechanical and morphological properties for polypropylene material (PP)

Al-Zubiedy Ali, Muneer Ruaa M.

Production Engineering Archives

|

2019

|

Vol. 24

20--24

EN

This is a study of a medical injection factory-Babylon carried out in order to achieve proper mechanical and morphological properties, PP has been injection molded by using cold runner injection molding machine with temperature variation (198, 200, 203……2200C) for ten samples. The physical and mechanical properties of PP product were examined. It has been found that the Shore hardness decreases linearly with injection molding temperature increasing. The tensile strength has a similar behavior to the hardness. However, it has been found that the MIF (Melt Index Flow) rates increases with the increase of injection molding temperature. The density of PP has been found for both virgin PP and the samples, it has been found that the density decreases with increasing operation temperature. FTIR (Fourier Transmission Infrared) spectra were taken for both samples with high and low operation temperature. Besides the SEM (Scanning Electronic Microscopy) test shows the difference in the morphology of the product surface and the PP product at high and low operation temperature. Moreover, for all these properties, the PP product exhibits good mechanical properties (hardness, tensile strength, density) for the samples produced at temperature lower than 2070C. While the physical properties such as MIF improved with injection temperature increasing, additionally, the SEM images show that the sample produced in low temperature have surface damage.

18

Możliwości stosowania fotopolimerowych form wtryskowych do produkcji małoseryjnej w strukturze Przemysł 4.0

Budzik Grzegorz, Żelechowski Damian

Polimery

|

2019

|

T. 64, nr 6

405--409

PL

Duża konkurencja wśród firm zajmujących się produkcją maszyn, urządzeń lub ich podzespołów sprawia, że niezwykle ważne stają się czynniki, takie jak: czas pojawienia się produktu na rynku, jego cena i jakość. Techniki szybkiego prototypowania, nieodzownie związane z ideą Przemysłu 4.0, nabierają więc ogromnego znaczenia. W pracy przedstawiono korzyści wynikające z zastosowania technologii PolyJet, oferowanej przez światowego lidera rynku druku 3D, firmę Stratasys, do wytwarzania detali metodą formowania wtryskowego do produkcji małoseryjnej.

EN

High competition among companies involved in the production of machines, devices or their components leads to the fact that such factors as the time of appearance of the product on the market, its price and quality are extremely important in the commercial market. Rapid prototyping techniques, being integrally associated with the idea of Industry 4.0, are of great importance in such a case. The work focuses on presenting the benefits coming from the use of PolyJet technology, offered by a world leader in the 3D printing market, Stratasys, for manufacturing of polymer parts using small scale injection molding.

19

Predicting effect of fiber orientation on chosen strength properties of wood-polymer composites

Frącz Wiesław, Janowski Grzegorz

Composites Theory and Practice

|

2019

|

R. 19, nr 2

56--63

EN

The paper presents an assessment of the effect of fiber orientation on the strength properties of products made from wood-polymer composites by the injection molding process based on micromechanical analysis. For this purpose numerical analysis was carried out for the product model with geometry of the sample intended for the uniaxial tensile test. To determine the actual fiber orientation after the manufacturing process, the orientation tensor values were calculated using Autodesk Moldflow Insight 2016 software. The micromechanical calculations were performed using Digimat FE commercial code. The results (stress-strain characteristics) of the numerical simulations taking into account the calculated fiber orientation tensor were compared to the experiment. To produce the wood-polymer composite, the polypropylene polymer matrix was Moplen HP 648T. As the filler Lignocel C120 wood fibers made by Rettenmeier & Sohns company were applied. A composite with a 10 vol.% content of wood fibers in the polymer was manufactured in the extrusion process by means of a Zamak EHP 25 extruder. For specimen manufacturing a Dr. Boy 55E injection molding machine equipped with a two cavity injection mold was used. Before the numerical simulations the uniaxial tensile test was performed using a Zwick Roell Z030 testing machine. The specimens were tested at the speed of 50 mm/min according to the PN-EN ISO 527 standard. The obtained stress-strain characteristics were used as a verification criterion for further numerical analysis. Moreover, the mechanical properties of the same composite products were predicted for hypothetical fiber orientation types. It was noted that the selection of fiber orientation has a significant impact on the quality of the obtained results compared to the experiment.

PL

Przedstawiono ocenę wpływu orientacji włókien na właściwości wytrzymałościowe wyrobów kompozytowych na przykładzie wyrobów z kompozytu typu drewno-polimer formowanych w technologii wtryskiwania. Przeprowadzono analizę numeryczną dla modelu wyrobu o geometrii próbki przeznaczonej do próby jednoosiowego rozciągania. W celu uzyskania danych o powtryskowej orientacji włókien w matrycy polimerowej przeprowadzono analizę numeryczną procesu wtryskiwania za pomocą oprogramowania Autodesk Moldflow Insigth 2016. Uzyskano w ten sposób wartości tensora orientacji włókien dla zadanych parametrów technologicznych procesu wytwarzania wyrobu. Obliczenia mikromechaniczne (analizy właściwości struktury kompozytu) przeprowadzono z wykorzystaniem oprogramowania Digimat FE. Wyniki analizy numerycznej dla obliczonej wartości tensora orientacji włókien porównano z eksperymentem. Ponadto, w celu ułatwienia definiowania w systemach CAE właściwości kompozytu wykonano prognozowanie jego właściwości mechanicznych dla hipotetycznych, uproszczonych przypadków orientacji włókien. Potwierdzono, iż dobór orientacji napełniacza (włókien) ma znaczący wpływ na zgodność prognozowanych właściwości kompozytu z wynikami badań eksperymentalnych.

20

Fiber shape selection problems in material models used in numerical strength analysis of wood-polymer composites

Frącz Wiesław, Janowski Grzegorz

Composites Theory and Practice

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2019

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R. 19, nr 2

50--55

EN

The paper presents the problems in selecting the fiber shape in numerical strength analysis for wood-polymer composites. For this purpose numerical analysis of the uniaxial tensile test for the wood-polymer composite sample was performed. Variable geometry of the fiber model was used. The fiber orientation data were obtained using Autodesk Moldflow Insight 2016 software. Micromechanical calculations based on homogenization methods were performed using Digimat FE commercial code. The results of the numerical simulations were compared with the experiment ones. To manufacture the WP composite, Moplen HP 648T polypropylene (PP) from Basell Orlen Polyolefins was used as the polymer matrix. As the filler 10 vol.% Lignocel C120 wood fiber manufactured by JRS - J. RETTENMAIER & Söhne Company was used. Adhesion promoter P613 by Dupont was used as well. A Dr Boy 55E injection molding machine was used to produce the test specimens. It was noted that the selection of the fiber shape has a significant impact on the consistency of the obtained results and consequently on compliance with the experiment ones. Fiber location calculations were performed for each geometry type available in the Digimat software. The most consistent results for numerical homogenization (Digimat FE) are associated with the choice of a curved cylinder shape of fiber. This may be due to the greatest convergence of the orientation tensor value received from the numerical simulation of the injection molding process during its transformations to the representative volume element model. In addition, this result may be due to the fact that the curved cylinder type of geometry is characterized by the most variable shape due to the degree of curvature. This reflects the real, non-standard problems to determine the shape of the wood fiber in the polymer matrix.

PL

Przedstawiono problematykę wyboru geometrii włókna w numerycznej analizie wytrzymałościowej kompozytu typu drewno-polimer. W tym celu przeprowadzono symulację próby jednoosiowego rozciągania dla próbek wykonanych z kompozytu polimerowo-drzewnego. Badano zmienną geometrię włókna, gdzie dane dotyczące orientacji włókien otrzymano z użyciem programu Autodesk Moldflow Insight 2016. Obliczenia mikromechaniczne opierające się na metodach homogenizacji przeprowadzono z użyciem programu Digimat FE. Wyniki otrzymane w symulacjach numerycznych porównano z eksperymentem. Stwierdzono, że dobór geometrii włókna w analizach numerycznych ma istotny wpływ na otrzymane wyniki, a w konsekwencji zgodność z eksperymentem.