멀티스케일 시뮬레이션을 이용한 탄소섬유강화 열가소성 복합재모재 표면함침 거동의 수치 해석

Abstract

This study proposes a multiscale simulation technique to predict matrix impregnation behavior during the insert injection molding process of Carbon Fiber Reinforced Thermoplastic Composites (CFRTP). To address impregnation issues caused by the high viscosity of thermoplastic resins and to ensure formability of complex-shaped parts, a top-down approach was applied. This approach links macroscale flow analysis results to mesoscale unit cell analysis boundary conditions. Microscale analysis was excluded as it is outside the scope of this study. The simulation results indicated that while complete impregnation was achieved near the gate due to high packing pressure, impregnation failure occurred towards the flow end due to rapid pressure drop and resin solidification. These simulation results showed qualitative agreement with the dry spots observed in actual insert injection molding experiments (Short shot tests). The analysis framework established in this study proves effective for optimizing processes and predicting defects in CFRTP parts.