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Modeling of Natural Fiber-Thermoplastic Composites Manufactured with Molding Processes

Modeling of Natural Fiber-Thermoplastic Composites Manufactured with Molding Processes. Laurent Matuana Workshop: Future of Modeling in Composites Molding Processes Co-Sponsored by NSF, DOE and APC June 9-10, 2004. Natural Fibers-Plastic Composites (NFPCs). 100% input control.

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Modeling of Natural Fiber-Thermoplastic Composites Manufactured with Molding Processes

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  1. Modeling of Natural Fiber-Thermoplastic Composites Manufactured with Molding Processes Laurent Matuana Workshop: Future of Modeling in Composites Molding Processes Co-Sponsored by NSF, DOE and APC June 9-10, 2004

  2. Natural Fibers-Plastic Composites (NFPCs)

  3. 100% input control Raw materials Step 1 Compounding Lack of on-line control Design Step 2 Manufacturing Step 3 Property testing 100% output control End products Bad Feed back Good Feed forward Current State of the Art

  4. Gaps • Limited information on material-process-property relationships for NFPCs, • Process models to predict the flow characteristics of the blends, formation of voids, alignment of fibers, and mechanical properties of NFPCs are almost inexistent, • Analytical models and computational simulation are not extensively used for NFPCs manufactured with molding processes.

  5. Modeling Issues with Natural Fibers • Non-uniform fibers • Difficult to characterize fiber source • Cross-section may be different between fibers and within a single fiber • Single fibers versus fiber bundles, both may be present • Non-rigid fibers • Long flexible fibers • Rigidity can change with temperature, moisture content • Fiber Attrition • Breakage can depend upon temperature, moisture content

  6. Future Directions • Process control and optimization • On line and non-destructive evaluation (NDE) of the properties of NFPCs • Flow visualization of NFPC blends • Process modeling and simulation by process data • Application of numerical analysis methods

  7. Future Directions (cont’d) • Develop a methodology for simulating the flow and other physico-mechanical properties of the composites, • Apply the methodology to evaluate the effects material components and processing conditions on the properties of the composites, • Define the range of applicability and the sensitivity to various input parameters for the methodology developed, • Assess the accuracy of the model and assumptions made in the deductions (i.e., sensitivity of empirical design parameters), • Develop design and manufacturing guides.

  8. Specific Research Trusts to Fill the Gaps • Integration of two different industries: • Forest products industry • Plastic industry • Multidisciplinary research for • modeling of physical phenomena within natural fibers and plastics during processing and use (e.g., adhesion, void formation, fiber alignment, physico-mechanical and flow properties, etc.), • Application of numerical analysis methods to various problems of NFPCs.

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