Finite element modelling and testing of an injection moulded generic tow reinforced structure

The deformation and fracture behaviour of a generic injection moulded structure reinforced by a robotically placed commingled glass fibre/polypropylene UD-tow (uni-directional) was simulated by finite elements. The suitability of modelling hybrid structures using features available within commercial finite element programs and standard material properties was assessed. Two different 2D modelling approaches based on shell and beam elements, which were computationally less intensive, were evaluated against 3D solid element models in both bending and flexure. It was shown that all three approaches predict the global deformation behaviour in both tension and bending compared with experimental data. Differences between the 2D and 3D approaches were mainly in the predicted stress distribution around the load introduction points.