An Approach to the Impact Simulation on Foamed Injection Molded Polypropylene Parts: An Example of Application in the Automotive Industry

Autor: Massimo Nutini, Markus Franzen, Mario Vitali
Jazyk: angličtina
Rok vydání: 2023
Předmět:
Zdroj: Polymers, Vol 15, Iss 4, p 936 (2023)
Druh dokumentu: article
ISSN: 2073-4360
DOI: 10.3390/polym15040936
Popis: An approach to the simulation of foamed injection molded Polypropylene parts subjected to impact loading is presented in this paper. The proposed method, which considers strain-rate-dependent material properties and the possible occurrence of fracture, is, in particular, suitable for parts manufactured with core-back technology. The method was developed to be used within the functionality of a commercial Finite Element solver using a shell-type element mesh. The material model is based on a three-layer structure, with two compact skin layers and a foamed core layer made of expanded material. The properties of the foamed material are assumed as those of the compact grade scaled by a suitable factor, which is identified via inverse engineering on a set of bending tests executed on specimens having different foam densities. The fracture of the material is then predicted using a damage model which considers the effects of triaxiality. The approach is then validated on industrial parts from the automotive sector, subjected to impact in a component test. Despite the simplicity of the presented approach, which makes this method suitable for industrial applications and especially for early-stage design, the validation shows a sufficiently accurate simulation of part behavior under the impact, with a reasonable prediction of damage and fracture.
Databáze: Directory of Open Access Journals
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