Injection molding is a widely used process for manufacturing a large range of polymer parts, including fiber-reinforced polymer composites. The complex nature of this process, combined with the non-Newtonian behavior of molten polymers, implies significant challenges in terms of control, prediction, and optimization of the processing parameters that influence manufacturing quality. While various computational and numerical models have been proposed to simulate the injection molding process and ensure the desired part quality (see, for instance, industrial software such as Moldex3D or Moldflow, they bring their own challenges, including high computational costs, the need for solver tuning, frequent parametric studies, and the economic burden associated with licensing.

In this study, machine learning surrogates are explored as an alternative to conventional modeling software. They are based on Graph Neural Networks (GNNs) that have recently demonstrated remarkable potential for simulating physical systems. In a graph, physical systems are encoded as nodes end edges, capturing their organization. Then, state-of-the-art techniques such as the message passing framework are tested for their potential to learn physics. In the long term, this project aims to establish a novel graph-based framework capable of efficiently simulating complex physics across various material models and processing conditions.

A numerical model is developed for 2D mold filling and quantitively validated against a benchmark. The prediction results demonstrate that the learned simulator is able to capture the physics of melt front behavior. Further, the prediction runtime is significantly faster than the ground truth, completing in under 1 second compared to \textasciitilde hours, representing a substantial improvement in efficiency. However, the accuracy of the predictions can vary, with errors accumulating especially during testing. While the scalar loss metric provides an estimate of the model's performance, it lacks expressiveness and can be unreliable on its own.

Delamination is a significant failure mode that has been the subject of extensive research in laminated structures. The interface in assembly structures often represents the susceptibly weak link and necessitates careful consideration to guarantee structural stability. It is of utmost significance to understand the behaviour of the delamination phenomenon and precisely evaluate the fracture toughness (resistance to delamination) in composites. Numerous test techniques have been established over time, some of which have been recognized and adopted as standards. The complexity associated with the standardized tests (crack tip monitoring, design configuration) and the limitations in the scope of testing various interface configurations have led to favoring of alternative testing methods in recent years. This thesis primarily aims at exploiting the new potentials of the Mandrel Peel Test method by incorporating the novel “Multi-Mandrel Concept” in determining the fracture toughness of the Thermoplastic Composites. Mandrel Peel test, a modified adaptation of the standard 90-degree peel test, presents as a promising technique for the delamination fracture testing of composites by determining the energy necessary for peeling off a flexible adherend (generally referred to as the peel-arm) from a rigid substrate. In this thesis, the objective was to further the understanding of the Mandrel Peel test, investigate the sensitivity of specimen configuration and testing parameters on different thermoplastic materials systems, and
evaluate the suitability of the Mandrel Peel test method for establishing a relationship between mandrel roller size and mixed mode fracture behavior. Comparative assessments were conducted between the multi-mandrel radii peel test and standardized tests, including DCB, ENF, and MMB tests. Experimental tests, fractography studies, and numerical validation were performed on UD GF/PP and UD CF/PPS composites.

The results show that the average fracture toughness values are slightly higher and more consistent for 2-ply peel arm specimens compared to 1-ply peel arm specimens. This is attributed to the microstructure (matrix and fiber distribution) at the interface and its influence on damage mechanism and fracture propagation behavior. The thickness of the ply also affects delamination propagation behavior and depends on the microstructure, with thicker plies exhibiting non-uniform fiber and matrix distribution. The experimental investigation reveals that the fracture toughness values increase as the mandrel
radius increases for UD GF/PP and UD CF/PPS composites with a 0|0 interface. The fracture toughness of CF/PPS peel specimens with a 0|90 interface shows limited variation
with respect to the mandrel radius. The relationship between mandrel radius and fracture toughness may not follow a linear trend, and it can depend on other factors such as material thickness, interface orientation, and fracture energy at pure loading modes. Comparative assessments between standardized tests and mandrel peel tests show similar trends in fracture toughness values with increasing mode mixture and mandrel roller radii.
Fractography analysis provides valuable insights into the fracture behavior of tested materials, and a correlation is identified between the failure modes observed in mixed-mode bending (MMB) tests and mandrel peel tests. The mandrel peel test enables establishing a relatively straight crack front during the delamination propagation, controlled by the mandrel’s kinematics, resulting in a more uniform distribution of strain energy across the specimen’s width, unlike standard tests.
The findings suggest that utilizing the multi-mandrel concept in assessing mixed-mode fracture toughness offers the possibility of extrapolating pure mode I and II fracture toughness values. This approach presents a viable tool for characterizing the fracture energy of composites with non-zero fiber-oriented interfaces that cannot be effectively assessed using classical tests. The results support the claim that mandrel roller size influences the degree of mode-mixity and suggests considering mandrel size when assessing mode-mixity in fracture phenomena.
Overall, this study provides valuable insights into the sensitivity of specimen configuration and testing parameters, the influence of mandrel roller size on mixed-mode fracture behavior, and the potential benefits of the mandrel peel test for delamination studies. By considering these findings, further advancements can be made in understanding and characterizing fracture properties in hybrid material systems.


Keywords: Delamination, fracture toughness, mixed-mode fracture, DCB, ENF,
MMB, Mandrel Peel test, thermoplastic composite, GF/PP, CF/PPS, Multi-
Mandrel Concept, peel arm, mandrel roller, mode mixity