'New and Advanced Models for Fiber Orientation'

The ability to predict flow-induced fiber orientation patterns is an essential step in the engineering of fiber-reinforced materials, because fiber orientation controls warping, shrinkage, and structural behavior.  A modification of Jeffery's equation, proposed by Folgar and Tucker (1984), was the first fiber orientation model to provide useful predictions, and has been the standard approach for modeling fiber orientation in Moldflow and other codes for many years.  Recently, greater availability of experimental data and interest in new material types has driven the development of improved fiber orientation models.  This talk will review the basics of fiber orientation modeling, and then show two new models.  The first, the Reduced Strain Closure (RSC) model, slows the kinetics of fiber alignment by an order of magnitude or more, greatly improving the prediction of core thickness in conventional short-fiber composites.  The second, using Anisotropic Rotary Diffusion (ARD), captures the types of orientation exhibited by long-fiber injection molding compounds.  These models will provide improved accuracy in the predictions of both fiber orientation and mechanical properties of injection molded composites.

'Importance of Upfront Engineering Using CAE Software for Emerging Plastics Processes'

The use of Moldflow software for conventional injection molding is very well established with good correlation even for complex parts.  There is also substantial improvement for predictive analysis for several new molding processes which is still not perfected and requires experience/knowledge for interpretation of results.  To meet OEM’s demand for cost reduction, appearance improvement, weight reduction (fuel economy), recycling, part integration etc., several variations in injection molding and new technologies have been developed.  Dr. Shah’s presentation will provide an overview of these advanced technologies such as Multi-material Molding, Co-Injection Molding, In-Mold Assembly, Micro-cellular Foaming Processes, Gas-Assisted Injection Molding, Water-Assisted Injection Molding, Liquid Silicon Molding, Thin-Wall Molding, IML Molding, Plastic/Metal Hybrid Technology, In-Line Material Compounding/Molding with Long Glass Fiber, Exjection Molding, Thermoset/Thermoplastic Injection Molding etc. For each technology, what customers want in terms of predictive analysis will be discussed along with the shortcomings of software and the reasoning behind it.  Also, the importance of using both plastics process simulation software and part performance predictive software simultaneously, which takes into account the anisotropic properties and non-linearity behavior of material, will be discussed.

'Year 2012 - The State of the Plastics Industry'

Reading the tea leaves of change is never easy - nor precise, but leaving your fate to chance is very risky.  The industry is going through such significant globalization, technological advances, and productivity changes that the industry of yesterday is not the industry of today.  The rate of change provides some interesting challenges and opportunities to the plastics industry.  Being financially strong and intelligent is not a guarantee of future success, but being adaptable is a key strength in periods of uncertainty.

Jeff Mengel will present some highlights of the 2007 North American Plastics Industry Study conducted by Plante & Moran that identify and benchmark some key performance indicators.  Jeff will also review some of the macro trends that are impacting the industry such as resin consumption, employment, and press capacity in North America versus the rest of the world.  Using projections from various sources and extrapolating the data into the future generates some interesting results.  Jeff will outline the possible future business models that will flourish in 2012 and the related key performance indicators.

Plastics are hardly ever processed in their natural state. An additive is usually used to enhance properties. One of the most common additives is colorant. In this presentation we take a look at the effect of colorants on material properties required for simulation. We show that new characterization techniques and material modeling techniques are able to capture the effect of such additives and so provide a basis for predicting the properties of colored material.