长玻纤增强塑料注射成型纤维断裂概述
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摘要
长玻纤增强塑料(LGFT)能有效改善塑料强度,拓展了塑料的应用范围;但注塑成型中常有纤维断裂的问题而影响玻纤增强效果。文中根据长玻纤增强塑料注射成型的研究成果,从材料、工艺、设备、数学模型和数值模拟方面介绍了注射成型对LGFT制品内玻纤长度的影响,总结了工艺参数及设备结构对纤维断裂的影响,以及纤维断裂模型的进展和数值模拟在纤维长度预测的应用,归纳了LGFT成型加工的适用范围和研究趋势。
Long glass fiber reinforced thermoplastics(LGFT) are now commercially available materials, which can demonstrate appreciable mechanical property premiums in more and more engineering applications. However, it is generally accepted that any fiber reinforced thermoplastic should be molded with a degree of care in order to preserve fiber aspect ratio in the final molded article and to minimize fiber length breakdown during processing. With the advent of the so called long fiber injection molding grades, it is even more important to have some further understanding of the glass fiber breaking mechanisms, if the long fiber benefits are to be realized in finished products. Based on the achievements of LGFT injection molding, the effects of fiber length, processing parameters and injection machine on the mechanical properties were reviewed. Meanwhile, the process parameters and equipment structures on fiber breakage were considered, especially stress on the development of fiber fracture mathematical models, numerical simulation and its application to predict the fiber length. Finally, the LGFT processing limits and the forecast trend of LGFT were briefly expounded, and their emphases of future research was described.
Long glass fiber reinforced thermoplastics(LGFT) are now commercially available materials, which can demonstrate appreciable mechanical property premiums in more and more engineering applications. However, it is generally accepted that any fiber reinforced thermoplastic should be molded with a degree of care in order to preserve fiber aspect ratio in the final molded article and to minimize fiber length breakdown during processing. With the advent of the so called long fiber injection molding grades, it is even more important to have some further understanding of the glass fiber breaking mechanisms, if the long fiber benefits are to be realized in finished products. Based on the achievements of LGFT injection molding, the effects of fiber length, processing parameters and injection machine on the mechanical properties were reviewed. Meanwhile, the process parameters and equipment structures on fiber breakage were considered, especially stress on the development of fiber fracture mathematical models, numerical simulation and its application to predict the fiber length. Finally, the LGFT processing limits and the forecast trend of LGFT were briefly expounded, and their emphases of future research was described.
引文
[1] Thomason J L.The influence of fiber length and concentration on the properties of glass fiber reinforced polypropylene:5.Injection moulded long and short fiber PP[J].Composites Part A,2002,33:1641-1652.
[2] 方鲲,张国荣,吴丝竹,等.长纤维增强热塑性复合材料在汽车零配件上的应用进展[J].中国塑料,2009,23(3):13-18.Fang K,Zhang G R,Wu S Z,et al.Application of long fiber reinforced thermoplastic composites in auto parts[J].China Plastics,2009,23(3):13-18.
[3] Bailey R,Kraft H.A study of fibre attrition in the processing of long fibre reinforced thermoplastics[J].Int.Polym.Process.,1987,2:94-101.
[4] Kelly A,Tyson W R.Tensile properties of fibre-reinforced metals:copper/tungsten and copper/molybdenum[J].J.Mech.Phys.Solids,1965,13:329-350.
[5] 段召华,付祥,陈弦,等.长玻璃纤维增强聚丙烯[J].高分子材料科学与工程,2010,26(4):124-126.Duan Z H,Fu X,Chen X,et al.Long glass fiber reinforced thermoplastics[J].Polymer Materials Science & Engineering,2010,26(4):124-126.
[6] Thomason J L.The influence of fibre length,diameter and concentration on the impact performance of long glass-fibre reinforced polyamide 6,6[J].Composites Part A,2009,40:114-124.
[7] Kumar K S,Ghosh A K,Bhatnagar N.Mechanical properties of injection molded long fiber polypropylene composites,part 1:tensile and flexural properties[J].Polym.Compos.,2007,28:259-266.
[8] Kumar K S,Bhatnagar N,Ghosh A K.Mechanical properties of injection molded long fiber polypropylene composites,Part 2:impact and fracture toughness[J].Polym.Compos.,2008,29:525-533.
[9] Yilmazer U,Cansever M.Effects of processing conditions on the fiber length distribution and mechanical properties of glass fiber reinforced nylon-6[J].Polym.Compos.,2002,23:61-71.
[10] Rohde M,Ebel A,Wolff-Fabris F,et al.Influence of processing parameters on the fiber length and impact properties of injection molded long glass fiber reinforced polypropylene[J].Int.Polym.Processi.,2011,26:292-303.
[11] 张宇,段召华,陈弦,等.注塑工艺参数对长玻纤增强 PA66 复合材料力学性能的影响[J].塑料科技,2011,39(2):65-69.Zhang Y,Duan S H,Chen X,et al.Effects of injection molding parameters on mechanical properties of long glass fiber reinforced PA66 composites[J].Plastics Science and Technology,2011,39(2):65-69.
[12] 陈生超,杨永良,陈金涛,等.纤维含量对长玻纤增强聚丙烯注塑制品性能影响[J].工程塑料应用,2013,41(12):44-48.Chen S C,Yang Y L,Chen J T,et al.Effect of fiber content on the performance of long glass fiber reinforced polypropylene injection molding products[J].Engineering Plastics Application,2013,41(12):44-48.
[13] Patcharaphun S,Opaskornkul G.Characterization of fiber length distribution in short and long glass fiber reinforced polypropylene during injection molding process[J].Kasetsart J.Nat.Sci.,2008,42:392-397.
[14] Inberg J P F,Hunse P H,Gaymans R J.Long fiber reinforcement of polypropylene / polystyrene blends[J].Polym.Eng.Sci.,1999,39:340-346.
[15] Gupta V B,Mittal P K,Sharma P K,et al.Some Studies on glass fiber-reinforced polypropylene.part I:reduction in fiber length during processing[J].Polym.Compos.,1989,10:8-15.
[16] Inoue A,Morita K,Tanaka T,et al.Effect of screw design on fiber breakage and dispersion in injection-molded long glass fiber reinforced polypropylene[J].J.Compos.Mater.,2015,49:75-84.
[17] O'Regan D,Akay M.The distribution of fibre lengths in injection moulded polyamide composite components[J].J.Mater.Process.Technology,1996,56:282-291.
[18] 张志坚,龚颖,卢康利,等.玻纤含量对长纤维增强聚丙烯性能的影响[J].工程塑料应用,2013,41(1):44-48.Zhang Z J,Gong Y,Lu K L,et al.Effect of glass fiber content on the properties of long fiber reinforced polypropylene[J].Engineering Plastics Application,2013,41(1):44-48.
[19] 马旭辉,邱能兴,韩静.长玻璃纤维增强聚丙烯复合材料的研究[J].塑料科技,2013,41(12):65-68.Ma X H,Qiu N X,Han J.Study on long glass reinforced polypropylene composites[J].Plastics Science and Technology,2013,41(12):65-68.
[20] Thomason J L.The influence of fiber length and concentration on the properties of glass fiber reinforced polypropylene.6.The properties of injection moulded long fiber PP at high fiber content[J].Composites Part A,2005,36:995-1003.
[21] Ren P,Dai G.Fiber dispersion and breakage in deep screw channel during processing of long fiber-reinforced polypropylene[J].Fibers Polym.,2014,15:1507-1516.
[22] Jeffery G B.The motion of ellipsoidal particles immersed in a viscous fluid[J].Proc.R.Soc.Lond.A,1922,102:161-179.
[23] Forgacs O L,Mason S G.Particle motions in sheared suspensions:IX.Spin and deformation of threadlike particles[J].J.Colloid Sci.,1959,14:457-472.
[24] Salinas A,Pittman J F T.Bending and breaking fibers in sheared suspensions[J].Polym.Eng.Sci.,1981,21:23-31.
[25] Shon K,White J L.A comparative study of fiber breakage in compounding glass fiber-reinforced thermoplastics in a buss kneader,modular corotating and counter-rotating twin screw extruders[J].Polym.Eng.Sci.,1999,39:1757-1768.
[26] Shon K,Liu D,White J L.Experimental studies and modeling of development of dispersion and fiber damage in continuous compounding[J].Int.Polym.Process.,2005,20:322-331.
[27] Inceoglu F,Ville J,Ghamri N,et al.Correlation between processing conditions and fiber breakage during compounding of glass fiber‐reinforced polyamide[J].Polym.Compos.,2011,32:1842-1850.
[28] Ville J,Inceoglu F,Ghamri N,et al.A study of fiber breakage during compounding in a Buss kneader[J].Int.Polym.Process.,2012,27:245-251.
[29] Shimizu Y,Arai S,Itoyama T,et al.Experimental analysis of the kneading disk region in a co‐rotating twin screw extruder:Part 2.glass‐fiber degradation during compounding[J].Adv.Polym.Technol.,1997,16:25-32.
[30] Bumm S H,White J L,Isayev A I.Glass fiber breakup in corotating twin screw extruder:simulation and experiment[J].Polym.Compos.,2012,33:2147-2158.
[31] Dinh S M,Armstrong R C.A rheological equation of state for semi-concentrated fiber suspensions[J].J.Rheol.,1984,28:207-227.
[32] Phelps J H,El-Rahman A I A,Kunc V,et al.A model for fiber length attrition in injection-molded long-fiber composites[J].Composites Part A,2013,51:11-21.
[33] Nguyen B N,Kunc V,Jin X,et al.Injection-molded long-fiber thermoplastic composites:from process modeling to prediction of mechanical properties[R].Oak Ridge,TN (United States):Oak Ridge National Laboratory (ORNL),2013.
[34] Jin X S,Wang J.Fiber breakage calculation for injection molded long fiber composites[C]// Annual Technical Conference Proceedings.Bethel:SPE ANTEC 2011,2011:1579-1583.
[35] Hopmann C,Weber M,van Haag J,et al.A validation of the fiber orientation and fiber length attrition prediction for long fiber-reinforced thermoplastics[C]//Jana S C.AIP Conference Proceedings.Cleveland:AIP Publishing LLC,2015,1664:050008-1-5.
[36] Tseng H C,Chang R Y,Hsu C H.Numerical predictions of fiber orientation and mechanical properties for injection-molded long-glass-fiber thermoplastic composites[J].Compos.Sci.Technol.,2017,150:181-186.
[2] 方鲲,张国荣,吴丝竹,等.长纤维增强热塑性复合材料在汽车零配件上的应用进展[J].中国塑料,2009,23(3):13-18.Fang K,Zhang G R,Wu S Z,et al.Application of long fiber reinforced thermoplastic composites in auto parts[J].China Plastics,2009,23(3):13-18.
[3] Bailey R,Kraft H.A study of fibre attrition in the processing of long fibre reinforced thermoplastics[J].Int.Polym.Process.,1987,2:94-101.
[4] Kelly A,Tyson W R.Tensile properties of fibre-reinforced metals:copper/tungsten and copper/molybdenum[J].J.Mech.Phys.Solids,1965,13:329-350.
[5] 段召华,付祥,陈弦,等.长玻璃纤维增强聚丙烯[J].高分子材料科学与工程,2010,26(4):124-126.Duan Z H,Fu X,Chen X,et al.Long glass fiber reinforced thermoplastics[J].Polymer Materials Science & Engineering,2010,26(4):124-126.
[6] Thomason J L.The influence of fibre length,diameter and concentration on the impact performance of long glass-fibre reinforced polyamide 6,6[J].Composites Part A,2009,40:114-124.
[7] Kumar K S,Ghosh A K,Bhatnagar N.Mechanical properties of injection molded long fiber polypropylene composites,part 1:tensile and flexural properties[J].Polym.Compos.,2007,28:259-266.
[8] Kumar K S,Bhatnagar N,Ghosh A K.Mechanical properties of injection molded long fiber polypropylene composites,Part 2:impact and fracture toughness[J].Polym.Compos.,2008,29:525-533.
[9] Yilmazer U,Cansever M.Effects of processing conditions on the fiber length distribution and mechanical properties of glass fiber reinforced nylon-6[J].Polym.Compos.,2002,23:61-71.
[10] Rohde M,Ebel A,Wolff-Fabris F,et al.Influence of processing parameters on the fiber length and impact properties of injection molded long glass fiber reinforced polypropylene[J].Int.Polym.Processi.,2011,26:292-303.
[11] 张宇,段召华,陈弦,等.注塑工艺参数对长玻纤增强 PA66 复合材料力学性能的影响[J].塑料科技,2011,39(2):65-69.Zhang Y,Duan S H,Chen X,et al.Effects of injection molding parameters on mechanical properties of long glass fiber reinforced PA66 composites[J].Plastics Science and Technology,2011,39(2):65-69.
[12] 陈生超,杨永良,陈金涛,等.纤维含量对长玻纤增强聚丙烯注塑制品性能影响[J].工程塑料应用,2013,41(12):44-48.Chen S C,Yang Y L,Chen J T,et al.Effect of fiber content on the performance of long glass fiber reinforced polypropylene injection molding products[J].Engineering Plastics Application,2013,41(12):44-48.
[13] Patcharaphun S,Opaskornkul G.Characterization of fiber length distribution in short and long glass fiber reinforced polypropylene during injection molding process[J].Kasetsart J.Nat.Sci.,2008,42:392-397.
[14] Inberg J P F,Hunse P H,Gaymans R J.Long fiber reinforcement of polypropylene / polystyrene blends[J].Polym.Eng.Sci.,1999,39:340-346.
[15] Gupta V B,Mittal P K,Sharma P K,et al.Some Studies on glass fiber-reinforced polypropylene.part I:reduction in fiber length during processing[J].Polym.Compos.,1989,10:8-15.
[16] Inoue A,Morita K,Tanaka T,et al.Effect of screw design on fiber breakage and dispersion in injection-molded long glass fiber reinforced polypropylene[J].J.Compos.Mater.,2015,49:75-84.
[17] O'Regan D,Akay M.The distribution of fibre lengths in injection moulded polyamide composite components[J].J.Mater.Process.Technology,1996,56:282-291.
[18] 张志坚,龚颖,卢康利,等.玻纤含量对长纤维增强聚丙烯性能的影响[J].工程塑料应用,2013,41(1):44-48.Zhang Z J,Gong Y,Lu K L,et al.Effect of glass fiber content on the properties of long fiber reinforced polypropylene[J].Engineering Plastics Application,2013,41(1):44-48.
[19] 马旭辉,邱能兴,韩静.长玻璃纤维增强聚丙烯复合材料的研究[J].塑料科技,2013,41(12):65-68.Ma X H,Qiu N X,Han J.Study on long glass reinforced polypropylene composites[J].Plastics Science and Technology,2013,41(12):65-68.
[20] Thomason J L.The influence of fiber length and concentration on the properties of glass fiber reinforced polypropylene.6.The properties of injection moulded long fiber PP at high fiber content[J].Composites Part A,2005,36:995-1003.
[21] Ren P,Dai G.Fiber dispersion and breakage in deep screw channel during processing of long fiber-reinforced polypropylene[J].Fibers Polym.,2014,15:1507-1516.
[22] Jeffery G B.The motion of ellipsoidal particles immersed in a viscous fluid[J].Proc.R.Soc.Lond.A,1922,102:161-179.
[23] Forgacs O L,Mason S G.Particle motions in sheared suspensions:IX.Spin and deformation of threadlike particles[J].J.Colloid Sci.,1959,14:457-472.
[24] Salinas A,Pittman J F T.Bending and breaking fibers in sheared suspensions[J].Polym.Eng.Sci.,1981,21:23-31.
[25] Shon K,White J L.A comparative study of fiber breakage in compounding glass fiber-reinforced thermoplastics in a buss kneader,modular corotating and counter-rotating twin screw extruders[J].Polym.Eng.Sci.,1999,39:1757-1768.
[26] Shon K,Liu D,White J L.Experimental studies and modeling of development of dispersion and fiber damage in continuous compounding[J].Int.Polym.Process.,2005,20:322-331.
[27] Inceoglu F,Ville J,Ghamri N,et al.Correlation between processing conditions and fiber breakage during compounding of glass fiber‐reinforced polyamide[J].Polym.Compos.,2011,32:1842-1850.
[28] Ville J,Inceoglu F,Ghamri N,et al.A study of fiber breakage during compounding in a Buss kneader[J].Int.Polym.Process.,2012,27:245-251.
[29] Shimizu Y,Arai S,Itoyama T,et al.Experimental analysis of the kneading disk region in a co‐rotating twin screw extruder:Part 2.glass‐fiber degradation during compounding[J].Adv.Polym.Technol.,1997,16:25-32.
[30] Bumm S H,White J L,Isayev A I.Glass fiber breakup in corotating twin screw extruder:simulation and experiment[J].Polym.Compos.,2012,33:2147-2158.
[31] Dinh S M,Armstrong R C.A rheological equation of state for semi-concentrated fiber suspensions[J].J.Rheol.,1984,28:207-227.
[32] Phelps J H,El-Rahman A I A,Kunc V,et al.A model for fiber length attrition in injection-molded long-fiber composites[J].Composites Part A,2013,51:11-21.
[33] Nguyen B N,Kunc V,Jin X,et al.Injection-molded long-fiber thermoplastic composites:from process modeling to prediction of mechanical properties[R].Oak Ridge,TN (United States):Oak Ridge National Laboratory (ORNL),2013.
[34] Jin X S,Wang J.Fiber breakage calculation for injection molded long fiber composites[C]// Annual Technical Conference Proceedings.Bethel:SPE ANTEC 2011,2011:1579-1583.
[35] Hopmann C,Weber M,van Haag J,et al.A validation of the fiber orientation and fiber length attrition prediction for long fiber-reinforced thermoplastics[C]//Jana S C.AIP Conference Proceedings.Cleveland:AIP Publishing LLC,2015,1664:050008-1-5.
[36] Tseng H C,Chang R Y,Hsu C H.Numerical predictions of fiber orientation and mechanical properties for injection-molded long-glass-fiber thermoplastic composites[J].Compos.Sci.Technol.,2017,150:181-186.