Composite Pultrusion Die Tooling & Fiber Volume Calculator
Calculate fiber volume fraction (V_f), required roving spool count (N), fiber weight fraction (W_f), hydraulic pulling resistance, and heated die entrance taper angles for FRP and carbon fiber profiles.
1. Input Parameters
2. Calculation Results
3. Geometric Visualizer
Tooling & Vector Prepress Engineering Notes
1. Fiber Volume Fraction Equation: The total number of roving spools is $N = \frac{V_f \cdot A \cdot \rho_{\text{fiber}}}{\text{TEX} \times 10^{-4}}$. High structural profiles target $V_f = 55\% - 65\%$.
2. Die Lead-In Compaction Zone: Heated pultrusion dies feature a $1.0^\circ - 2.5^\circ$ entrance bell-mouth taper extending $50 - 100\text{ mm}$ to compact wet-out fibers without fiber shearing or dry spots.
3. Profile Chrome Plating: Die cavity DXFs must allow $0.05 - 0.08\text{ mm}$ for hard chrome plating ($70\text{ HRC}$) polished to $Ra < 0.1\,\mu\text{m}$ (SPI A1 mirror finish).