Predicting molding forces during sheet molding compound (SMC) compression molding. II: Effect of SMC composition

One of the fastest-growing applications of SMC compression molding is the manufacture of truck body panels. Because of their large size, the molding forces required are substantial and have a major influence on the molding cycle. Also, as SMC moves towards parts requiring higher strength, the fiber length and percentage by weight of fibers must increase. This will also contribute to larger molding forces. In this paper, a procedure is presented to evaluate the SMC rheological parameters needed to predict molding forces. In addition, the effect of SMC composition on the molding forces is investigated. In particular, we evaluate the effect of reinforcement type (glass versus carbon) and level, filler level and thickener level. It was found that the factors most affecting molding forces are the reinforcement length and level, and the filler level. In addition, it was discovered that for SMC thickened with magnesium oxide, the level of thickener does not affect the molding force.