Development of an injection molding method for the production of highly oriented test specimens

Bachelor- or Master thesis

Short-fiber-reinforced thermoplastics (SFT) are predominantly processed using the injection molding process, as this method enables the economical, high-quality and automatic production of components. Due to the flow conditions within the melt, however, a layer structure with different fiber orientations is created across the wall thickness. This local anisotropy makes it difficult to experimentally investigate material fatigue under oscillating load, as the orientation of the fibers has a considerable influence on the micromechanical damage mechanisms present. For the investigation of fatigue behavior, a suitable injection molding tool is therefore to be developed with which it is possible to produce a tube geometry with a homogeneous, highly oriented fiber orientation. With a thesis at IKV, you have the opportunity to acquire comprehensive knowledge of the injection molding process and the development of injection molds and thus contribute to the further development of the process.

© IKV

The work is related to this research project:

The fatigue mechanisms in short-fiber-reinforced plastics are not yet fully understood. For this reason, components fail prematurely, are replaced early or have to be over-dimensioned using large amounts of material in order to ensure operational stability. As part of the working group, you will contribute to research into material fatigue and thus support IKV in developing methods for safe dimensioning, taking sustainability into account.

Objective:

The ideal flow conditions in the mold cavity have already been determined on the basis of numerical preliminary investigations so that a homogeneous, highly oriented fiber orientation distribution can be achieved in a tube specimen. The aim of your work will be to derive requirements for the mould design based on these investigations and to design a modular mould that realizes these flow conditions. You will systematically solve various design tasks, prepare the production and assembly of components and test a prototype of the Mould on the injection molding machine. Subsequent tests on the injection molding machine ultimately lead to an iterative improvement of the mold inserts based on the fiber orientation distribution that forms. You will document the design methodology you use, which enables the transfer of the results of the numerical preliminary investigations, in a Bachelor’s or Master’s thesis.

Your task:

Your profile:

• Engineering studies
• Independent, solution-oriented and creative way of working
• Interest in design work and existing CAD knowledge
• Ideally initial experience in injection molding

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