An enhanced demand for lightweight materials in automotive applications has resulted in the growth of the use of injection molded discontinuous fiber-reinforced thermoplastics. During the intensive injection molding process, severe fiber breakage arises in the plasticating stage leading to a broad fiber length distribution. Fiber orientation distribution (FOD) is another highly anisotropic feature of the final injection molded parts induced by the mold filling process. The mechanical and other properties can be highly dependent on the fiber length distribution and fiber orientation distribution.

The residual fiber length in the final part is of great significance determining the mechanical performances of injection molded discontinuous fiber reinforced thermoplastic composites. One goal of this research is to develop a fiber length characterization method with reproducible sampling procedure in a timely manner is described. In this work is also proposed an automatic fiber length measurement algorithm supported by Matlab®. The accuracy of this automatic algorithm is evaluated by comparing the measured results using this in-house developed tool with the manual measurement and good agreement between the two methods is observed.

Accurate predictions of fiber orientation are also important for the improvement of mold design and processing parameters to optimize mechanical performances of fiber-reinforced thermoplastics. In various fiber orientation models, a strain reduction factor is usually applied to match the slower fiber orientation evolution observed experimentally. In this research, a variable strain reduction factor is determined locally by the corresponding local flow-type and used in fiber orientation simulation. The application of the variable strain reduction factor in fiber orientation simulations for both non-lubricated squeeze flow and injection molded center-gated disk, allows the simulated fiber re-orient rate to be dependent on the local flow-type. This empirical variable strain reduction factor might help to improve the fiber orientation predictions especially in complex flow, because it can reflect the different rates at which fibers orient during different flow conditions.

Finally, the stiffness of injection-molded long-fiber thermoplastics is investigated by micro-mechanical methods: the Halpin-Tsai (HT) model and the Mori-Tanaka model based on Eshelby's equivalent inclusion (EMT). We proposed an empirical model to evaluate the effective fibers aspect ratio in the computation for the fiber bundles under high fiber content in the as-formed fiber composites. After the correction, the analytical predictions had good agreement with the experimental stiffness values from tensile tests on the composites. Our analysis shows that it is essential to incorporate the effect of the presence of fiber bundles to accurately predict the composite properties.