A validated computational framework for investigating the manufacturing heterogeneities induced from injection molding

Document Type

Article

Publication Date

7-15-2026

Abstract

Short fiber reinforced thermoplastic composites are widely used in aerospace, automotive, and construction applications due to their high strength, stiffness, and recyclability. Predicting their buckling behavior is challenging because of manufacturing induced anisotropy, including fiber orientation gradients and weldline effects. This study presents an integrated manufacturing to buckling computational framework combining mold flow simulations, Mori-Tanaka based micromechanical mapping, and finite element analysis. A rate dependent anisotropic viscoplastic model was developed, implemented in Fortran, and calibrated against experimental tensile data. The framework was hierarchically validated through material calibration, experimental bracket tests, and analytical buckling verification. It was applied to hollow PA6-GF40 columns with variable cross-sections, capturing the impact of fiber orientation and weldline induced stiffness discontinuities on global stability. Results demonstrate that process induced microstructural features significantly affect buckling performance, establishing a direct link between processing parameters and structural instability.

Publication Source (Journal or Book title)

International Journal of Mechanical Sciences

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