CAE method for compression molding of carbon fiber-reinforced thermoplastic composite using bulk materials

There has been great interest in using fiber-reinforced polymer composites to develop lightweight components for automotive applications. Compression molding of carbon fiber (CF) reinforced thermoplastic is one of the preferred processes, as it offers the opportunity to maintain a longer fiber length and higher volume production. We have developed a unique computer aided engineering (CAE) method by utilizing viscoelastic structural analysis to accurately predict the warpage behavior of fiber-reinforced thermoplastic material under the compression molding process from a bulk charge format. A prototype structure with complex geometry was designed and manufactured for validation purposes. The fiber orientation and warpage results from both the CAE and actual part were compared to verify the accuracy of the CAE method. Additional studies related to the charge footprint effect were also conducted for the compression molding process on the same materials. The developed method and tools are expected to help in expediting the development of lightweight carbon fiber-reinforced thermoplastic parts.