Three-dimensional finite-element analysis of the compression molding of sheet molding compound

Abstract

In order to analyze the compression molding of SMC (sheet molding compound) at room temperature, a three-dimensional finite-element program was developed based on the rigid-viscoplastic approach. The accuracy of the program developed was tested by solving the axi-symmetric compression of a cylindrical specimen of SMC and the three-dimensional compression of rectangular specimens of aluminum alloys under various processing conditions. The simulation results compared well with experimental results obtained from compression tests and with data available in the literature. Based on these comparisons the program was proven to be valid and was further applied in the simulation of the compression molding of rectangular SMC specimens to investigate the effect of friction and molding speeds on the propagation of the flow front of the material and the load requirements in the present investigation. By coupling part of the program with thermal analysis, the currently-developed analysis program can be utilized in determining detailed information during three-dimensional deformation processes.