STRUCTURAL ANALYSIS OF FIBER- FILLED PLASTICS

WITH MOULDING PROCESS INDUCED ANISOTROPY

P. Satheesh Kumar1, S. Srikari2, N. S. Mahesh3, S. Reddy4
Student, M. Sc. [Engg.], 2Professor, 3Professor and Center Manager (AMT and EMM),
M.S. Ramaiah School of Advanced Studies, Bangalore 560 054
4
Senior Analyst, Schneider Electric India Pvt. Ltd.

Abstract
Thermoplastics have many advantages over metal parts, including lower mass and ease of fabrication. To further
improve their elastic modulus, creep resistance, and dimensional stability, short fibers are added to polymers. Such
composites find widespread use because they can be processed with techniques used for unfilled polymers, provided the
fiber length is below a certain limit. However, the application of fiber-filled thermoplastic materials has been limited in
many cases by the inability to accurately predict performance and durability.
In this work, structural analysis capability of ANSYS is used in conjunction with flow simulation capability of
Moldflow. The Moldflow fiber orientation simulation model allows significantly improved prediction of orientation of
fibers in a molded component over a range of polymer materials and fiber contents. The ANSYS interface for Moldflow is
used to translate this information to an input file for structural analysis using ANSYS. With effect of fiber orientation
incorporated in the material properties, results of this structural analysis provide more realistic valuse of deformation and
stresses in the formed part.
Linear orthotropic analysis is carried out on ash tray door component by coupling Moldflow with ANSYS. A
comparison is made between the results from linear isotropic and linear orthotropic analysis with different gating systems
to understand the effect of these parameters on the mechanical performance of the part. Simulation results are able to
predict the observed mechanical behaviour of short-fiber filled plastic components when the anisotropy of the material is
taken into consideration. Traditional approach of treating the material property as isotropy overestimates the stiffness of
the part. Also, modelling of flow is able to quantify the anisotropy generated in the part during its fabrication process.
Keywords: Fiber Filled Plastic, Fiber Orientation, Anisotropic, Orthotropic, Moldflow, ANSYS
Abbreviations
CAD
Computer-Aided Design
CAE
Computer-Aided Engineering

during the transient mold filling is important for the

prediction of such anisotropic properties of final plastic
part.

1. INTRODUCTION

One of the complicating factors for injectionmolded plastic parts is the change in the properties of
plastics during the manufacturing process. While this is
not a problem in and of itself, problems can arise if the
structural analyses are based on generic material data
that does not accurately represent the actual properties
of the molded part. This can lead to over engineering of
components, resulting in increased costs and material
usage, or under-engineering, which can result in
premature failure of parts.

The automotive industry is on the brink of a

revolution, and the plastics industry is poised to play a
major role. New technologies are enabling
improvements in safety, comfort and savings in energy.
Lightweight plastics allow automotive designers and
engineers the freedom to deliver innovative concepts
cost effectively. From an aesthetic perspective, plastics
and plastic composites offer the automotive designers
distinct advantages in many applications. Plastics
provide versatile designs in electrical, electronic, and
lighting applications, further enhancing new styling
opportunities. Versatility is core to plastics' beauty,
allowing for efficient design through consolidation of
parts and their modularity, reducing parts manufacturing
costs and enhancing vehicle affordability [1].

When glass or carbon fibers are added to plastics,

the elastic modulus can increase significantly with a
negligible effect on part weight. This combination of
low weight and high stiffness makes fiber-filled plastics
ideal for high-performance applications. The orientation
direction and the degree of orientation of the fibers
determine the mechanical properties of the molded part.
The material will have higher strength in the direction in
which majority of the fibers are aligned, but will be
relatively weak in the direction perpendicular to it
(across the fibers). In areas where fibers are randomly
oriented, the material will not achieve maximum
strength and the material will exhibit isotropic
behaviour.

Short-fiber reinforced composites are widely used

for their high strength to weight ratios and remarkably
enhanced physical properties compared with pure
polymer products. Compression molding, extrusion and
injection molding are some of the processes often used
for fabricating components of short-fiber reinforced
composites. The fibers are suspended in the polymer
matrix, and during manufacturing process orient
themselves in response to the interactions among
kinematics of the flow, other neighboring fibers and
mold cavity. Fiber reinforced composites typically show
anisotropic mechanical, thermal and rheological
properties. Therefore, prediction of fiber orientation

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During injection molding process, the fibers in the

plastic melt will orient in different directions under the
influence of shear forces resulting from flow patterns.
This will result in material properties being different at
different locations of the part.

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Fig. 1 Velocity and shear rate profile of melt [2]

For effective design of short-fiber reinforced
polymer based composites, CAE (Computer Aided
Engineering) can play an important role. Characteristics
of polymer and particle-contained suspensions being
highly nonlinear and complex, only CAE can provide
reasonable solutions. This technique offers a detailed
and accurate simulation of processes in shorter time and
lesser cost than traditional experiments and tests. The
results can be used to identify the areas where
orientation of the fibers is not suitable for a design.
However, most commercial packages use rather
simplified models and approximate numerical
algorithms to calculate fiber orientation distribution.
Refinement in modelling and numerical prediction of
fiber suspension for better prediction is one area of
focus for current research activities. This paper
describes the use of such a tool for the design of a
typical component.

Fig. 2 Fiber orientation along thickness [2]

A number of researchers have studied the flow
induced anisotropy in fiber-filled plastics employing
analytical and experimental methods. Recently,
experimental techniques and numerical studies have
been carried to compare the isotropic and orthotropic
behaviors of a fiber-filled plastic bolt. Kancharla et al.
[3] conducted flow and structural analysis on a plastic
bolt, using Moldflow and Abaqus. Their results showed
that the simulation results with orthotropic property
were within 4% of experimental results (Fig. 3).
According to them this proves the capability of
orthotropic structural analysis in predicting the results
accurately for a short fiber filled thermoplastic material.

Figures 1 and 2 show the velocity profile and fiber

orientation for a melt flow across thickness. The fibers
in the mix get oriented along the local velocity vector
and because of the variation of velocity across the
thickness the fiber orientation also varies across the
thickness of the part. This results in anisotropy of
modulus of the part based on the local orientation of the
fibers.

Fig. 3 Variation of deflection with pressure [3]

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The literature reveals the need for analysis of flow

induced anisotropy for improving design and
performance of fibre-filled material. Due to the complex
flow behaviour very few computational studies have
been reported previously. In the current work, numerical
simulations of an ash tray door component have been
carried out to provide an insight into the physics of the
flow characteristics and structural performance of a
filled material. An effort has also been made to
understand the flow details with different gating
numbers and locations to understand the influence of
gating and resulting differences in weld line.
In this paper, results of modelling and simulation
of fiber-filled plastics with process induced anisotropy
have been presented. Moldflow [5] has been used to
simulate the manufacturing process (injection molding)
and ANSYS has been used to simulate the structural
performance of the part. The study has been carried out
on an ash tray door component for three different cases,
as described below, and results have been compared.

Fig. 4 Geometric model of the ash tray door

Chung and Kwon [4] carried out finite element
analysis for fiber suspensions using Pseudo
Concentration method as a melt-front capturing
technique. They found that including fountain flow
effect induces wide core layers of orientation
distributions and consequently simulation results match
experimental data. Also, the coupling effect between
fluid and fiber is important near the core and transition
layers, even far downstream in the flow direction. The
numerical studies of viscoelastic polymer dynamics
must accompany with general 3D geometry because of
the importance of melt front or gate region on the
orientation states. Also, experimental data for various
complex geometries must be obtained to understand
detailed orientation dynamics and rheology. It was
stated that suspension rheology and particle dynamics
must be understood for more highly concentrated
suspensions in the near future, then fiber to fiber
interaction could be better understood.

Case 1: Structural analysis with isotropic property

Case 2: Single gate molding analysis (Structural

analysis with orthotropic properties)

Case 3: Two gate molding analysis (Structural

analysis with orthotropic properties)

2. GEOMETRIC MODEL
The geometric model of the component used for
this study, an ash tray door used in automobiles, is
shown in Fig. 4. This component can be seen in the rear
door of a car as a closing door for the ash tray. The part
thickness varies from 0.6 mm to 2.5 mm.

Fig. 5 Methodology for ash tray door analysis

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about 1.31 mm (Fig.7) with a maximum stress of 80

MPa (Fig. 8).

Fig. 6 Boundary conditions used for structural

analysis
2.1 Analysis Methodology
Figure 5 details the analysis methodology to
conduct the flow and structural analysis. In the first part
of the methodology, molding of the component is
modelled using Moldflow. The results of this analysis,
which includes information about fiber orientation, is
then exported to ANSYS where finite element model for
structural analysis is created. For orthotropic analysis,
Information about fiber orientation, obtained from
Moldflow analysis, is used to determine the material
stiffness property at any point in the model.

Fig. 8 Stress variation for isotropic material

properties

Fig. 9 Single gate runner and cooling system

3.2 Case 2: Single Gate Flow Analysis

Fig. 7 Displacement variation for isotropic

material properties

The flow analysis was carried out with single gate

submarine with hot drop system (Fig. 9). Hot water at
90C was used to maintain the mold temperature.

2.2 Details of the Numerical Model

ANSYS was used to carried out the structural
analysis. The CAD model was imported into Ansys and
meshed with solid 187 tetrahedral elements. Boundary
conditions were specified in ANSYS (Fig. 6) and first
an analysis with linear isotropic material properties was
carried out to get the deflection and stress results (Case
1). The material specified for the analysis was Arnite
TV4 270 GF 35% from DSM Plastics with a modulus of
11500 MPa. A load of 500 N was applied on the center
of the door to get the deflection there while the edges of
the door were constrained.

Table 1. Moldflow boundary conditions for ash

tray door molding

3. ANALYSIS RESULTS

The boundary conditions used for the mold filling

analysis are shown in Table 1.

Material
Melt temperature
Mold temperature
Injection time
Switch-over Velocity/Pressure
Pressure
Packing/Holding
Time
Cooling Time

3.1 Case 1: Structural Analysis with Isotropic

Material Properties

Amite TV4 270

260 C
90 C
12 s
98%
80%
4s
25 s

The maximum displacement obtained from the

structural analysis with isotropic material properties was

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Fig. 11 Variation of modulus for single gate

molding

Fig. 10(a) Mold filling pattern for single gate

molding

The variation of modulus in the third principle

direction (loading direction), a function of fiber
orientation, over the ash tray door, obtained from the
filling analysis is shown in Fig. 11. From the plot it is
clear that the modulus is varying throughout the part
length and thickness. The plot shows a maximum
modulus of 6024 MPa against the actual material
modulus of 11500 MPa. This was mainly due to the
orientation effect of the fibers. The fibers are well
oriented in the first and second principle direction but
not in the third direction. Approximately, a reduction of
45% in modulus was observed. This is expected to
affect the structural behaviour of the part.
The variation in modulus through the thickness of
the part is presented in Fig.12. The two curves, Curve_1
and Curve_2, show the variation of modulus through the
thickness of the part at two points P1 and P2
respectively. The location of these points is also
identified in Figure 12.

Fig. 10(b) Fiber orientation pattern for single

gate molding
The filling and fiber orientation pattern obtained
from the mold filling analysis is shown in Fig. 10(a) and
10(b). The fiber orientation plot indicates that the fibers
are oriented in different directions and angle with
different densities.

Fig. 12 Through thickness modulus variation for single gate molding

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3.3 Case 2: Structural analysis with orthotropic

material properties of part molded with single gate
After the flow analysis was completed, the
numerical model was taken to ANSYS with the mapped
orthotropic properties for structural analysis. The
loading conditions were kept same as were used for
Case 1.

Fig. 15 Two gate runner and cooling system

Fig. 13 Displacement variation for orthotropic

material properties, Single gate molding

Fig. 16(a) Mold filling pattern for two gate

molding
The filling pattern and fiber orientation obtained
from the two gate mold filling analysis are shown in
Fig. 16(a) and 16(b). Melt joining is observed in the
center of the part which will result in a weld line. The
variation of modulus induced due to fiber orientation
across the part and through the thickness are shown in
Fig. 17 and 18 respectively.

Fig. 14 Stress variation for orthotropic material

properties, Single gate molding
The maximum displacement obtained from the
analysis was about 2.78 mm (Fig. 13) with a maximum
stress of 85 MPa (Fig. 14). The analysis results confirm
the expected reduction in the stiffness of the part
because of the way fibers are oriented in the molded
part. Orientation of the fibers in the loading direction
resulted in almost halving the modulus in that direction.
Correspondingly, the displacement increased and more
than doubled.
3.4 Case3: Two Gate Flow Analysis
To understand the influence of number of gates,
gate location and weld line on fiber orientation and
modulus of the part, the flow analysis was carried out
with two gates (submarine gating) with hot drop system.
In this design, water at 90 C was used to maintain the
mold temperature. The door component with two
submarine gates and cooling system is shown in Fig. 15.
Flow analysis was carried out with the same boundary
condition as in Case 2 to evaluate the filling and fiber
orientation characteristics.
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Fig. 16 (b) Fiber orientation pattern for two

gate molding

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Fig. 20 Stress variation for orthotropic material

properties, two gate molding

Fig. 17 Variation of modulus for two gate

molding

The maximum displacement obtained from the

Case 3 analysis was about 2.43 mm (Fig. 19) with a
maximum stress of 95 MPa (Fig. 20). As in Case 2, in
this case also, the analysis captures the reduction in the
stiffness of the component because of its orthotropic
properties. However, it can be observed that a change
in mold design, from one gate to two gate mold,
changes the fiber orientation pattern in a way that makes
the component stiffer despite the presence of a weld
line. In fact, variation of modulus through the thickness
shows that modulus on the weld line area is higher
because of different fiber orientation patterns.
Moreover, at the centre of the part, the melt from both
the gates join and continue to flow further which make
them to fuse properly, resulting in a higher modulus.

Table 2. Maximum displacement in the ash tray

door for the three cases

Fig. 18 Through thickness modulus variation

for twp gate molding
3.5 Case 3: Structural analysis with orthotropic
material properties of part molded with two gates

Case

After the flow analysis was completed with two

gate system, the numerical model was taken to ANSYS
with the mapped orthotropic properties for structural
analysis. The loading conditions were kept same as in
Case 1 and Case 2.

Description
Structural analysis
with
isotropic
property
Structural analysis,
1 gate molding,
with
orthotropic
property
Structural analysis,
2 gate molding,
with
orthotropic
property

sp
(mm)

%
difference

1.31

-----

2.78

52

2.42

45

4. RESULTS AND DISCUSSIONS

Maximum displacements for the three different
cases considered in this study are presented in Table 2.
These simulation results are able to capture the observed
effect of anisotropy on the mechanical behaviour of
molded short-fiber reinforced plastic components. As
can be seen from the results, simulation of molding
process with one gate die and subsequent structural
analysis predict almost halving of he stiffness of the
component. Changing to a two gate design of the
molding die improves the stiffness only marginally.
However, in both the cases, the simulation models are
able to capture the observed behaviour of the
component.

Fig. 19 Displacement variation for orthotropic

material properties, two gate molding

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Based on these results, it can be concluded that the

simulation tools, for molding process and for structural
analysis with orthotropic material properties, can be
successfully used in tandem to predict the mechanical
behaviour of molded components made out of shortfiber composites. It is important that this approach is
used, rather than designing the component assuming the
material property to be isotropic, because the
approximation can be very erroneous.

5. CONCLUSIONS
Based on the simulation results presented above,
the following conclusions were drawn:

A finite element modelling approach can be used to

predict the influence of process induced anisotropy
in fiber-filled plastic parts.

Anisotropy induced due to manufacturing process

has a major impact on mechanical performance of
a component.

In a molded part, fiber orientation and density, both

governed by flow pattern in the mold, result in
modulus value different at different points in the
part, and also, different in three principle directions
at the same point.

Anisotropy can change the stiffness characteristics

of a part by more than 50%.

Material anisotropy is affected by the flow pattern

in mold. Hence, change in mold design can be used
to tailor the stiffness characteristics of a part.

6. REFERENCES
[1] http://www.popsci.com/cars/article/200409/plastics-automotive-markets-vision-andtechnology-roadmap, Retrieved on 25-Jun-09
[2] Interface to CAE structural software- Moldflow
iMUG May-08, Slide No.15 and 16.
[3] Ashok K Kancharla, Harindranath Sharma K, and
Paul Nugent, Orthotropic Structural Analysis of
Short Fiber Filled Thermoplastics: AbaqusMoldflow Interface, Experimental Validation,
SIMULIA India Regional Users Meet, 2009.
[4] Du Hwan Chung and Tai Hun Kwon, Fiber
Orientation in the Processing of Polymer
Composites, Korea-Australia Rheology Journal
Vol. 14, No. 4, pp. 175-188, December 2002.
[5] Autodesk, Moldflow and Moldx-3D reference
manuals and help files, Autodesk Moldflow 2010

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