Initial Design Iteration Both structural finite element and injection mold simulations were used to evaluate and drive the bracket design. Initial simulations to develop the design assumed smear isotropic properties for both the continuous composite and the injection molded base. The initial FEA model, shown in Figure 4, assumes an ideal connection at the interface between the continuous laminate and the injection molded base. Simulations are performed at Altair Product Design using Abaqus/standard and OptiStruct and at Safran Cabin using Femap, Nastran and LS-Dyna. The bracket is assumed to be mounted to a rigid plate through 4 bolt locations. A force load is applied through a pin in the large hole of the laminate composite plates. There were 6 load cases as described in Figure 5. The paper will focus on one load case to illustrate the process as illustrated in the screening test fixture in Figure 6. While the initial assumptions provide guidance on the overall performance more detail is incorporated into the modeling techniques during the life of the program. Different methodologies are being investigated to model the interface at the composite insert and molded part, development work continues in this area and will be reported in a separate publication. An injection mold simulation is used to develop a balanced fill. Simulations are performed by Kruse Analysis using Moldex 3d software. Care was given in designing cutouts in the inserts to avoid gas entrapment and reduce the development of butt weld lines. A short fill is shown in Figure 7. The simulations modeled the inserts as rigid elements. Initially 15 iterations were run to look at flow development and to develop the cutout design. Later in the redesign process emphasis was modeling the development of the bond area. The quality of the bond is determined as a function of the temperature at the interface, temperatures at the insert need to be above the melt temperature of the PAEK laminate. Stress at the interface, assuming ideal bond, is also shown in Figure 7. Revised Design Iteration 2 During initial development it was determined that injection mold filling patterns influenced the bond and insert stability. Where stability refers to shifting or deforming of the composite insert. Our overall load capacity of the bracket was very close to our targets, but the quality showed some inconsistencies and was deemed not a production stable process. A design revision is developed with the following goals: w w w. s a m p e . o r g Figure 6. Screening test set-up. Figure 7. Injection mold process simulation and structural simulation. * Improve part quality * Improve bonding to continuous composite * Reduce voids * Reduce insert deformation * Improve load capability M A R C H /A P R I L 2 0 2 0 | SAMPE JOURNAL | 19http://www.sampe.org