Quantification of the Influence of Charge Variations on the Flow Behavior of Sheet Molding Compounds

Using a newly developed flow test bench, several charge configurations were analyzed to quantify the influence of the charge configuration in the mold in sheet molding compound (SMC) manufacturing. A test bench was developed to satisfy the industrial needs for the incoming goods inspection as well as the need for the flow characterization of rheological models in the simulation. The test setup has a cylindrical opening for the charge placement, from where the material is pressed into a thin flow channel, forcing the material to reorient. A comparison was performed by juxtaposing the resulting compression pressure recorded during the process. The charge for this test series, placed into the cylindrical opening, has two basal configurations, one consisting of a stack of disks, and the second in a rectangular sheet rolled up into a spiral. Six charge variations were tested in total. The amount of material, the batch, the layering and the production direction of the sheet proved to have a significant influence on the necessary compression pressure. Guidelines about the recommended charge configurations could be derived for optimized production settings, such as a reduction in the compression pressure and modifications to the charge.