Process induces fiber orientation: Numerical simulation with experimental verification

Abstract The performance of short fiber molded composite structures is determined uniquely by the properties of the molding material and the process induced fiber orientation. Consequently, the capability to accurately predict the fiber orientation distribution is of fundamental importance in computer‐aided mold design. Methodology for the numerical prediction of fiber orientation during the mold‐fill process is presented for a short glass fiber thermoset (57 percent phenolic resin, 10 percent calcium carbonate filler, and 33 percent glass fiber by volume). On the basis of a finite element flow characterization, Jeffery's orientation equation is numerically integrated along streamlines to calculate fiber orientation. Correlation of experimental and numerical results for an end‐gated bar with a molded‐in hole is reasonably good.