Effect of Mold Temperature and Fiber Velocity on Resin Impregnation and Fracture Resistance in Basalt Fiber‐Polypropylene Composites Through Integrated Mathematical Modeling

ABSTRACT Basalt fiber‐reinforced polypropylene composites offer promising applications due to their recyclability, mechanical strength, and thermal stability. This study develops an integrated mathematical model combining Darcy's law, the Reynolds equation, the Weibull distribution, the cohesive zone model, and Griffith's criterion to predict resin impregnation quality and fiber fracture behavior under varying processing conditions. Basalt fiber‐reinforced polypropylene composite samples were fabricated at mold temperatures of 240°C, 250°C, and 260°C, with fiber velocities ranging from 0.5 to 1.5 m/min. The optimal processing condition was identified at 260°C and 0.5 m/min, where the porosity reached as low a value and the fiber fracture rate was minimized to 1.69%. Model predictions showed strong agreement with experimental results, with error margins between 0.71% and 4.55% across different analyses. These findings highlight the critical role of controlled mold temperature and fiber velocities in enhancing impregnation efficiency and mechanical integrity in Basalt fiber‐reinforced polypropylene composites, offering a reliable framework for process optimization in thermoplastic composite manufacturing.