Rheological characterization and macroscopic modeling and simulation of the molding process of a PA6 Glass Mat Thermoplastic (GMT)

This study targets the characterization and modeling of GMT press molding. The targeted material is TEPEX® flowcore, a long glass fiber mat reinforced polyamide (PA6/GF) manufactured by Lanxess. Press molding of flowcore comprises the sequential stages of material forming and material flow, including challenges like local wrinkling and incomplete mold filling, respectively. Therefore, a sequential modeling approach using a Lagrangian and an Eulerian discretization is pursued. Rheological characterization using rheometer setups and in-mold viscosity measurements reveals a significant anisotropy of viscosity resulting from the predominantly in-plane fiber alignment. Anisotropy of viscosity is successfully modeled and parameterized, enabling a unified material modeling for material forming and material flow. Good predictions are observed for both wrinkling and flow. In , molding simulation results reveal that the isotropic modeling of viscosity is sufficient for flow simulation, whereas considering the anisotropic viscosity is essential for the accurate prediction of material forming.