Sheet Molding Compound processing: Characterization and numerical representation of the flow behavior

This dissertation aims to optimize the flow behavior of Sheet Molding Compound (SMC) for lightweight applications, addressing EU environmental goals. SMC offers high specific strength and stiffness, and potential for integrating recycled fibers, but its performance is influenced by fiber orientation and therefore, by the material flow during compression molding. The research introduces a new procedure for characterizing SMC rheology for process simulations, considering material variability while being industrially applicable. A new flow test bench was developed to study the out-of-plane flow of different charge configurations, revealing that separating sheets in the flow direction reduces compression pressure and avoids defects. The investigations also highlight the importance of fiber orientation. Validating the new material cards showed that simulations align well with real-world flow, advancing SMC process simulation and supporting the use of recycled fibers.