Effect of static mixer on fiber orientation of injection molded fiber-reinforced composites

Demitri Shotwell, Allen Jonathan Román, Huaguang Yang, Chung Yin Lin, Stefanie Glas, Edward Chen, Tim A. Osswald, Lih Sheng Turng*

*Corresponding author for this work

Research output: Contribution to journalJournal Article peer-review

3 Scopus citations

Abstract

The effect of an in-mold static mixer on orientation of fiber-reinforced polypropylene (PP) was explored within the injection molding process. Several mold geometries and helical mixer designs were assessed via simulation to identify the mixing ability and the potential effect on fiber orientation. It was found that the static mixers within the runner segment could successfully mix the polymer and randomize the fibers but that the fiber alignment reduction was quickly recovered. Injection molding experiments were carried out to verify these simulations using one geometry case. Fiber orientation at different mold locations were measured using micro-CT (μCT) scans and the degree of fiber orientation was quantified by “goodness of fit” to a normal Gaussian function approach. The experimental fiber orientation results showed good agreement with the simulations. These experiments indicated that the use of a static mixer within the runner system of a mold could be used for mixing the polymer melt after the plasticizing unit of the injection molding machine. However, its effect on changing the overall alignment of the fibers within injection molded parts could be offset by the melt flow downstream of the static mixer, suggesting the importance of mixer location with respect to the part cavity.

Original languageEnglish
Pages (from-to)192-207
Number of pages16
JournalSPE Polymers
Volume3
Issue number4
DOIs
StatePublished - 10 2022
Externally publishedYes

Bibliographical note

Publisher Copyright:
© 2022 The Authors. SPE Polymers published by Wiley Periodicals LLC on behalf of Society of Plastics Engineers.

Keywords

  • fiber orientation
  • injection molding
  • micro-CT (μCT) scans
  • static mixer

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