Numerical investigation of the effects of chopped carbon fiber bundle dimensions on properties of sheet molding compound

Recent research highlights the influence of chopped carbon fiber (CF) bundle dimensions on Sheet Molding Compound (SMC) properties. This study employs a meso -scale finite element method (FEM), integrating a compaction modeling approach to capture non-uniform morphology. A central line method tracks bundle movement during compression, compiling orientation statistics. Employing a full test coupon-sized meso -scale model for analysis, results consistently align with experiments, indicating enhanced tensile and flexural performance in SMC with thinner or narrower CF bundles, attributed to a more uniform filler distribution and increased bundle interactions. However, no definitive relationship is observed between out-of-plane orientation and these properties. Despite omitting interface effects and resin flow during compression, the numerical analyses offer insights into SMC’s structure-properties relationship, advancing high-performance material development.