Device, system and method for modeling fiber orientation distribution

An injection molding system, comprising:

• a mold having a mold cavity;
• a molding machine configured to fill the mold cavity with a composite molding resin including a polymeric material having a plurality of cylindrical fibers and a plurality of non-cylindrical fibers, wherein the cylindrical fibers have first geometry data and first fiber data and the non-cylindrical fibers have second geometry data and second fiber data;
• a computing device, being connected to the molding machine and comprising:
• a memory, being configured to store an orientation distribution generation model;
• an input interface, being configured to receive the first geometry data and the first fiber data of a cylindrical fiber and the second geometry data and the second fiber data of a non-cylindrical fiber;
• a processor, being connected to the memory and the input interface electrically and configured to:
• derive a cylindrical fiber orientation distribution by inputting the first geometry data and the first fiber data of the cylindrical fiber into an orientation distribution generation model;
• where the cylindrical fiber orientation distribution has a first shell width and a first core width, wherein the first fiber data of the cylindrical fiber includes a first fiber-to-fiber interaction parameter, a first fiber-to-polymer interaction parameter, and a first fiber slow-down rate parameter;
• select a second fiber data of the non-cylindrical fiber based on the first fiber data, the first shell width and the first core width of the cylindrical fiber;
• wherein the second fiber data includes a second fiber-to-fiber interaction parameter, a second fiber-to-polymer interaction parameter, and a second fiber slow-down rate parameter;
• calculate an aspect ratio of the non-cylindrical fibers based on the second geometry data of the non-cylindrical fiber;
• and
• derive a non-cylindrical fiber orientation distribution by inputting the aspect ratio and the second fiber data of the non-cylindrical fiber into the orientation distribution generation model, wherein the non-cylindrical fiber orientation distribution has a second shell width and a second core width, wherein the second core width is larger than the first core width, the second shell width is smaller than the first shell width;
• a controller, being connected to the computing device and configured to control the molding machine to perform an actual molding for injecting the composite molding resin into at least a portion of the mold cavity based on the non-cylindrical fiber orientation distribution.

A method for modeling fiber orientation distribution related to an injection molding object, comprising:

• deriving a cylindrical fiber orientation distribution by inputting first geometry data and first fiber data of the cylindrical fiber into an orientation distribution generation model;
• where the cylindrical fiber orientation distribution has a first shell width and a first core width, wherein the first fiber data of the cylindrical fiber includes a first fiber-to-fiber interaction parameter, a first fiber-to-polymer interaction parameter, and a first fiber slow-down rate parameter;
• selecting a second fiber data of the non-cylindrical fiber based on the first fiber data, the first shell width and the first core width of the cylindrical fiber;
• wherein the second fiber data includes a second fiber-to-fiber interaction parameter, a second fiber-to-polymer interaction parameter, and a second fiber slow-down rate parameter;
• obtaining an aspect ratio of a non-cylindrical fiber based on the second geometry data of the non-cylindrical fiber;
• inputting the aspect ratio and second fiber data of the non-cylindrical fiber into the orientation distribution generation model for outputting a non-cylindrical fiber orientation distribution, wherein the non-cylindrical fiber orientation distribution has a second shell width and a second core width, wherein the second core width is larger than the first core width, the second shell width is smaller than the first shell width.