A boundary element analysis of flow in sheet molding compound

Abstract A new boundary element method has been developed for analyzing the flow of sheet molding compound (SMC) during compression molding. The boundary element equations can be used to determine the velocities on the perimeter of the charge. Successive flow front configurations are then generated by a simple explicit updating procedure. This approach was used to predict the flow front progression for elliptical, rectangular, and L‐shaped charges. Comparisons with experimental data for elliptical and rectangular charges were encouraging. The fact that it was possible to obtain reasonable agreement for charges with different shapes and thicknesses lends support to the underlying flow model. Furthermore, valuable insight regarding knit line formation was acquired by analyzing the L‐shaped charge. Results from the boundary element analysis showed that the initial thickness of the charge has a pronounced effect on knit line development. Even though there is considerable industrial experience in making SMC parts, the important role of charge thickness on knit line formation appears to have been largely overlooked. Prior analyses gave no indication of this effect because they were based on lubrication models that were independent of charge thickness.