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Sandwich injection moulding offers the possibility of combining materials with different properties and, for instance, hide a recycled constituent within a virgin ditto. This attractive potential puts great demands on the manufacturing and therefore also on the process modelling. In particular the effect on the final stress state and the deformation of the part due to the heterogeneity of the material must be clarified. This topic is addressed in this study. To start with it is confirmed that expressions for the temperature field can be much simplified without major loss of accuracy in the solution. This enables us to take an analytical approach to the modelling and the resulting equations can be solved on a spread-sheet or with a simple code. It is also shown that the derived models compare well to experiments made with a two-layered structure, indicating that the models presented can be used to estimate changes of processing conditions or material properties for sandwich structures.

Modelling of Residual Stresses and Warpage in Sandwich Injection Moulding