Academic literature on the topic 'Thermoplastic fibre-reinforced composites – Manufacturing system'
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Journal articles on the topic "Thermoplastic fibre-reinforced composites – Manufacturing system"
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Köhler, Thomas, Tim Röding, Thomas Gries, and Gunnar Seide. "An Overview of Impregnation Methods for Carbon Fibre Reinforced Thermoplastics." Key Engineering Materials 742 (July 2017): 473–81. http://dx.doi.org/10.4028/www.scientific.net/kem.742.473.
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Carbon fibre reinforced plastics (CFRPs) can be classified according to whether the matrix is a thermoset or a thermoplastic. Thermoset-matrix composites are by tradition far more common, but thermoplastic-matrix composites are gaining in importance. There are several techniques for combining carbon fibres with a thermoplastic-matrix system. The composite’s characteristics as well as its manufacturing costs are dependent on the impregnation technique of the carbon fibre and the textile structure respectively. Carbon fibre reinforced thermoplastics (CFRTPs) are suitable for fast and economic production of high-performance components. Despite the higher material costs thermoplastic-matrix systems show cost benefits in comparison to thermoset-matrix due to substantial time savings in the production process. Moreover CFRTPs can be manufactured in large production runs. The commingling of reinforcement fibres with matrix fibres is a well-established process. Another approach is the coating of the carbon fibre with a thermoplastic subsequent to the carbon fibre production (carbonization, activation and deposition of sizing). The latter point is currently subject of research and is a promising method for further increasing the production speed. This paper presents the different possibilities of impregnating carbon fibres with a thermoplastic matrix. Diverse technologies along the process chain of the CFRTP production will be discussed.
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Kolonko, Angelika, Frank Helbig, Jürgen Tröltzsch, Daisy Nestler, and Lothar Kroll. "Torque-Fiber-Winding (TFW)-Procedure: Manufacturing of Textile-Based Unidirectional Prepreg for Raw Material and Material Development of Carbon Fibre Reinforced Thermoplastics." Key Engineering Materials 742 (July 2017): 498–505. http://dx.doi.org/10.4028/www.scientific.net/kem.742.498.
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There is the need to determine the process capability of available and novel carbon fibre (CF) roving with minimal material and reproducible procedures in the field of research and development of continuous fibre reinforced composites and structural components, as well as to identify the power delivery in thermoplastic laminate constructions. The innovative TFW procedure with the appropriate system technology allows the production of piece size variable unidirectional (UD) prepreg in a continuous sequential process of spiral winding. A flexible surface design, resulting in the partial fixation of a single highly spread CF roving on fine nonwoven fabric. By defined accumulating of composite components, the fibre volume content (FVC) is adjustable and correspond to the level of spreading and to the grammage of nonwoven fabric. Minimum single layer thickness promote compound homogeneity and thereby allow the generation of greatest possible degrees of freedom in load-oriented structural design of CF-reinforced thermoplastic lightweight products in the laboratory staff.
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Neugebauer, Reimund, Verena Kräusel, and Alexander Graf. "Process Chains for Fibre Metal Laminates." Advanced Materials Research 1018 (September 2014): 285–92. http://dx.doi.org/10.4028/www.scientific.net/amr.1018.285.
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The combination of fibre-reinforced materials with metals is defined as a fibre metal laminate. These material composites have already been a subject of research for several years. The long manufacturing time resulting from the period required for consolidation of the thermosetting resin is a major disadvantage of the fibre metal laminates previously in use (for instance GLARE, which is a combination of aluminium with glass fibre-reinforced plastic). In this paper, a new fibre metal laminate with a thermoplastic resin in the carbon fibre-reinforced plastics (CFRP) is introduced. The application of a thermoplastic resin system results in a general change in the process chain. The cutting of fibre metal laminates by means of the flexible water jet and laser cutting techniques is presented. In the second operation, forming behaviour is represented by the methods of v-bending and deep drawing. Finally, quality assurance by means of computed tomography, which replaces the conventional metallographic method, is described.
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Karapepas, Christos, Maik Trautmann, Andreas Todt, Amar Al-Obaidi, Sebastian Nendel, Verena Kräusel, and Guntram Wagner. "Development of Tailored Hybrid Laminates: Manufacturing of Basalt Fibre Reinforced Thermoplastic Orthoses with Aluminum Thin Sheets." Key Engineering Materials 809 (June 2019): 245–52. http://dx.doi.org/10.4028/www.scientific.net/kem.809.245.
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Nowadays, orthoses are made from fibre reinforced thermoset based composites with a high manual labor input. These thermoset based orthoses are no longer formable, which brings forth a significant disadvantage. Hence, hybrid laminates consisting of fibre reinforced thermoplastic films and thin metal sheets can replace successive thermoset based systems due to their advantages of higher formability and the suitability for mass production. In the present work, various surface treatment methods like pickling or mechanical blasting have been used on thin metal sheets to increase the adhesive and shear strength of the produced thermoplastic based hybrid laminates. The modified metal sheets were further combined with basalt fibre reinforced interlayers to manufacture overlap samples, which were used to determine the tensile shear strength. In addition, the roughness of the modified metal sheets has also been investigated. Moreover, the consolidation parameters such as pressure, holding time and temperature have been varied for the production of hybrid laminates using hot-pressing process and then the microstructural images have been recorded. Finally, the mechanical properties of the produced hybrid laminates have been tested by means of a three-point bending test and the interlaminar shear strength has been analyzed.
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Sexton, Anthony, Wesley Cantwell, Matthew Doolan, and Shankar Kalyanasundaram. "Investigation of the Deformation Behaviour of a Thermoplastic Fibre Metal Laminate." Materials Science Forum 773-774 (November 2013): 503–11. http://dx.doi.org/10.4028/www.scientific.net/msf.773-774.503.
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Fibre metal laminates are sandwich materials comprised of a fibre-reinforced composite and a metal alloy. These advanced materials offer superior properties compared to the monolithic constituents; primarily, improved specific strength and stiffness compared to metals and improved impact and fatigue resistance when compared to composite materials. The use of these advanced materials is currently restricted to specialised applications where the superior properties justify the high cost of manufacturing. The formability of a fibre metal laminate based on a glass fibre reinforced polypropylene and an aluminium alloy is investigated in this study using techniques developed for the evaluation of metallic materials. Specimens of varying geometry were stretched over a hemispherical punch and an open die configuration was used to facilitate the acquisition of the strain using a using an optical measurement system. The experimental results were used to determine a forming limit diagram and to elucidate the safe forming limits of the material. In addition, the effect of specimen geometry on deformation behaviour was investigated by analysing the evolution of strain on the surface of the specimens. A significant finding of this study is that advanced materials such as fibre metal laminates can be formed in a similar manner to monolithic metals.
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Lyu, Xiuqi, Yi Wan, Jun Takahashi, and Isamu Ohsawa. "Health condition evaluation of carbon fiber–reinforced thermoplastic with a tapping system." Journal of Thermoplastic Composite Materials 31, no. 7 (September 14, 2017): 959–73. http://dx.doi.org/10.1177/0892705717729196.
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Carbon fiber–reinforced thermoplastic (CFRTP) composites are gaining popularity in the manufacturing industry of lightweight automobiles. Common composite defects (e.g. voids and delamination) often occur inside CFRTP composites due to their inappropriate manufacturing process and long-term service. In this study, an instrumented tapping system was designed to evaluate the health condition of CFRTP composites by controlling the input force and velocity. The effective mathematical expressions of the contact duration and amplitude of the interactive force were derived to quantify the local stiffness of the tapping area. The amplitude of the interactive force was introduced innovatively as a significant evaluation parameter for a non-closed force–time curve with the time axis due to the influence of constraint condition and coupling effect of the modal shapes excited during tapping. The contact duration of the interactive force over the defective region was longer than that over the sound region. The amplitude of the interactive force applied on the defective area was observed to be lower than that on the sound area. In addition, the applicability and sensitivity of the amplitude of the interactive force was also investigated by changing the dimensions and locations of defects.
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Qin, Yang, John Summerscales, Jasper Graham-Jones, Maozhou Meng, and Richard Pemberton. "Monomer Selection for In Situ Polymerization Infusion Manufacture of Natural-Fiber Reinforced Thermoplastic-Matrix Marine Composites." Polymers 12, no. 12 (December 7, 2020): 2928. http://dx.doi.org/10.3390/polym12122928.
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Awareness of environmental issues has led to increasing interest from composite researchers in using “greener” materials to replace synthetic fiber reinforcements and petrochemical polymer matrices. Natural fiber bio-based thermoplastic composites could be an appropriate choice with advantages including reducing environmental impacts, using renewable resources and being recyclable. The choice of polymer matrix will significantly affect the cost, manufacturing process, mechanical properties and durability of the composite system. The criteria for appropriate monomers are based on the processing temperature and viscosity, polymer mechanical properties, recyclability, etc. This review considers the selection of thermoplastic monomers suitable for in situ polymerization during resin, now monomer, infusion under flexible tooling (RIFT, now MIFT), with a primary focus on marine composite applications. Given the systems currently available, methyl methacrylate (MMA) may be the most suitable monomer, especially for marine composites. MMA has low process temperatures, a long open window for infusion, and low moisture absorption. However, end-of-life recovery may be limited to matrix depolymerization. Bio-based MMA is likely to become commercially available in a few years. Polylactide (PLA) is an alternative infusible monomer, but the relatively high processing temperature may require expensive consumable materials and could compromise natural fiber properties.
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Hürkamp, André, Sebastian Gellrich, Tim Ossowski, Jan Beuscher, Sebastian Thiede, Christoph Herrmann, and Klaus Dröder. "Combining Simulation and Machine Learning as Digital Twin for the Manufacturing of Overmolded Thermoplastic Composites." Journal of Manufacturing and Materials Processing 4, no. 3 (September 11, 2020): 92. http://dx.doi.org/10.3390/jmmp4030092.
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The design and development of composite structures requires precise and robust manufacturing processes. Composite materials such as fiber reinforced thermoplastics (FRTP) provide a good balance between manufacturing time, mechanical performance and weight. In this contribution, we investigate the process combination of thermoforming FRTP sheets (organo sheets) and injection overmolding of short FRTP for automotive structures. The limiting factor in those structures is the bond strength between the organo sheet and the overmolded thermoplastic. Within this process chain, even small deviations of the process settings (e.g., temperature) can lead to significant defects in the structure. A cyber physical production system based framework for a digital twin combining simulation and machine learning is presented. Based on parametric Finite-Element-Method (FEM) studies, training data for machine learning methods are generated and a FEM surrogate is developed. A comparison of different data-driven methods yields information on the estimation accuracy of task-specific data-driven methods. Finally, in accordance with experimental cross tension tests, the investigated FEM surrogate model is able to predict the interface bond strength quality in dependence of the process settings. The visualization into different quality domains qualifies the presented approach as decision support.
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Rimmel, Oliver, David May, Christian Goergen, Artur Poeppel, and Peter Mitschang. "Development and validation of recycled carbon fiber-based binder tapes for automated tape laying processes." Journal of Composite Materials 53, no. 23 (December 24, 2018): 3257–68. http://dx.doi.org/10.1177/0021998318820422.
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The current growth in use of fiber reinforced polymer composites causes a strongly increasing amount of waste. Current approaches for fiber reinforced polymer composites recycling usually not exploit the potential of endless fibers as they are shortened during recycling and will not be properly aligned in the final product. Considering this, the present work aimed at the development of a recycling process for long recycled carbon fibers, where fiber length is preserved and load-related fiber orientation is possible. The starting point for the presented work was so-called slivers, which are long bundles of fibers resulting from a carding process that has been applied to fiber scrap. The main focus of this work was on the development of a binder mesh application rig that processes the sliver to a binder tape, processable in an automated tape laying process, which in turn required modifications to adapt to the novel tape. The functionality of the binder tape manufacturing process was validated with long recycled carbon fibers slivers with linear density of 4 g/m and fiber lengths between 70 and 120 mm. With the binder tape preform manufactured this way, two alternative routes for composite manufacturing were tested. First, the amount of binder was set so high that direct thermoplastic pressing of the preforms was possible. Second, the amount of binder was minimized, and the preforms were infiltrated with a thermoset resin system via resin transfer molding. While the thermoplastic route showed very deficient fiber–matrix adhesion, with the thermoset route, ≈68% of stiffness and ≈31% of strength of virgin fiber-based composites could be achieved in fiber direction in a unidirectional lay-up.
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Baho, Omar, Gilles Ausias, Yves Grohens, and Julien Férec. "Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters." International Journal of Advanced Manufacturing Technology 110, no. 7-8 (September 2020): 2105–17. http://dx.doi.org/10.1007/s00170-020-05876-9.
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Abstract Laser-assisted automated fiber placement (AFP) is highly suitable for an efficient production of thermoplastic-matrix composite parts, especially for aeronautic/aerospace applications. Heat input by laser heating provides many advantages such as better temperature controls and uniform heating projections. However, this laser beam distribution can be affected by the AFP head system, mainly at the roller level. In this paper, a new optico-thermal model is established to evaluate the laser energy quantity absorbed by a poly(ether ether ketone) reinforced with carbon fibers (APC-2). During the simulation process, the illuminated radiative material properties are characterized and evaluated in terms of the roller deformation, the tilt of the robot head, and the reflection phenomenon between the substrate and the incoming tape. After computing the radiative source term using a ray-tracing method, these data are used to predict the temperature distribution on both heated surfaces of the composite during the process. The results show that both the roller deformation and the tilt of head make it possible to focus the laser beam on a small area, which considerably affects the quality of the finished part. These findings demonstrate that this optico-thermal model can be used to predict numerically the insufficient heating area and thermoplastic composites heating law.
Dissertations / Theses on the topic "Thermoplastic fibre-reinforced composites – Manufacturing system"
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Claassen, Marius. "A reconfigurable manufacturing system for thermoplastic fibre-reinforced composite parts : a feasibility assessment." Thesis, Stellenbosch : Stellenbosch University, 2015. http://hdl.handle.net/10019.1/97045.
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Thesis (MEng)--Stellenbosch University, 2015.ENGLISH ABSTRACT: The South African manufacturing industry plays a pivotal role in the growth of its local economy. Modern manufacturing requirements include the ability to respond quickly to product variability, fluctuations in product demand and new process technologies. The reconfigurable manufacturing paradigm has been proposed to meet the demands of the new manufacturing requirements. In order to assess the feasibility of incorporating automated, reconfigurable manufacturing technologies into the production process of thermoplastic fibre-reinforced composite parts, a system, based on the thermoforming process, that implements these technologies was developed and evaluated. The assessment uses a seat pan for commercial aircraft as case study. Aspects that were addressed include the architecture, configuration and control of the system. The architecture and configuration addressed the sheet cutting, fixturing, reinforcing, heating, forming, quality assurance and transportation. The control, implemented using agents and based on the ADACOR holonic reference architecture, addresses the cell control requirements of the thermoforming process. An evaluation of the system’s reconfigurability and throughput is performed using KUKA Sim Pro. The evaluation of the system’s throughput is compared to the predicted throughput of the conventional technique for manufacturing thermoplastic fibre reinforced composite parts in a thermoforming process. The evaluation of the system’s performance show that the system designed in this thesis for the manufacture of a thermoplastic fibre-reinforced composite seat pan sports a significant advantage in terms of throughput rate, which demonstrates its technical feasibility. The evaluation of the system’s reconfigurability show that, through its ability to handle new hardware and product changes, it exhibits the reconfigurability characteristics of modularity, convertibility, integrability and scalability.
AFRIKAANSE OPSOMMING: Die Suid-Afrikaanse vervaardigingsbedryf speel 'n sentrale rol in die groei van die plaaslike ekonomie. Moderne vervaardiging vereistes sluit in die vermoë om vinnig te reageer op die produk veranderlikheid, skommelinge in die produk aanvraag en nuwe proses tegnologieë. Die herkonfigureerbare vervaardiging paradigma is voorgestel om te voldoen aan die nuwe produksie vereistes. Ten einde die uitvoerbaarheid van die integrasie van outomatiese, herkonfigureerbare vervaardiging-tegnologieë in die produksieproses van veselversterkte saamgestelde onderdele te evalueer, is 'n stelsel, gebaseer op die termo-vormingsproses, wat sulke tegnologieë implementeer, ontwikkel. Die assessering gebruik 'n sitplek pan vir kommersiële vliegtuie as gevallestudie. Aspekte wat aangespreek is sluit in die argitektuur, konfigurasie en beheer van die vervaardigingstelsel. Die argitektuur en konfigurasie spreek aan die sny, setmate, versterking, verwarming, vorm, gehalteversekering en vervoer van n veselversterkte saamgestelde sitplek pan in 'n termo-vormingsproses. Die beheer, geïmplementeer deur die gebruik van agente en gebaseer op die ADACOR holoniese verwysing argitektuur, spreek die selbeheervereistes van die termo-vormingsproses aan. 'n Evaluering van die stelsel se herkonfigureerbaarheid en deurvoer word gedoen met die behulp van KUKA Sim Pro. Die evaluering van die stelsel se deurvoer word vergelyk met die deurvoer van die konvensionele vervaardigingsproses vir termoplastiese vessel-versterkte saamgestelde onderdele in 'n termo-vormingsproses. Die evaluering van die stelsel se prestasie toon dat die stelsel wat in hierdie tesis ontwerp is vir die vervaardiging van 'n termoplastiese vessel-versterkte saamgestelde sitplek pan, hou 'n beduidende voordeel, in terme van deurvloeikoers, in wat die stelsel se tegniese haalbaarheid toon. Die evaluering van die stelsel se herkonfigureerbaarheid wys dat, deur middel van sy vermoë om nuwe hardeware en produk veranderinge te hanteer, die stelsel herkonfigureerbare einskappe van modulariteit, inwisselbaarheid, integreerbaarheid en skaalbaarheid vertoon.
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Crawley, Christopher Anthony. "Thermoforming of continuous fibre-reinforced thermoplastic composites." Thesis, University of Liverpool, 1996. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.263704.
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Mashau, Shivasi Christopher. "An investigation into the manufacturing of complex, three-dimensional components using continuous fibre reinforced thermoplastic composites." Thesis, 2017. https://hdl.handle.net/10539/24191.
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A dissertation submitted to the Faculty of Engineering and the Built Environment,
University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the
degree of Master of Science in Engineering.
Johannesburg, October 2017This research looks into the manufacturing process of complex geometries using continuous fibre reinforced thermoplastics (CFRTP). The purpose of this work was to develop methods that will enable the production of defect free complex components. This was achieved by investigating the key process parameters in the CFRTP manufacturing process, and optimizing them in order to improve the quality of components. The investi- gations were performed with the aid of software making use of the finite element method, and this was found to be instrumental in predicting the formability of geometries. The re- search showed that the formability of complex geometry is largely determined by the ability of the laminate to be draped into the required geometry. The forming mechanisms that take place during the draping process can be linked to the formation of defects where draping is unsuccessful. The study also showed that the quality of the drape can be influenced by blank and tool design factors. It was also shown that the blank can be manipulated using a restraint mechanism to improve the formability of geometries. The effect of processing parameters such as forming speed, forming pressure and tool temperature were also investigated. The research resulted in the formulation of guidelines to follow when manufacturing CFRTP components. The developments that were made were successfully implemented to improve the formability of a complex component that had previously been difficult to form without defects.
MT2018
Book chapters on the topic "Thermoplastic fibre-reinforced composites – Manufacturing system"
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Azaman, M. D., S. M. Sapuan, S. Sulaiman, E. S. Zainudin, and A. Khalina. "Processability of Wood Fibre-Filled Thermoplastic Composite Thin-Walled Parts Using Injection Moulding." In Manufacturing of Natural Fibre Reinforced Polymer Composites, 351–67. Cham: Springer International Publishing, 2015. http://dx.doi.org/10.1007/978-3-319-07944-8_17.
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Bar, Mahadev, R. Alagirusamy, and Apurba Das. "Advances in Natural Fibre Reinforced Thermoplastic Composite Manufacturing: Effect of Interface and Hybrid Yarn Structure on Composite Properties." In Advances in Natural Fibre Composites, 99–117. Cham: Springer International Publishing, 2017. http://dx.doi.org/10.1007/978-3-319-64641-1_10.
Full textConference papers on the topic "Thermoplastic fibre-reinforced composites – Manufacturing system"
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Kobayashi, Satoshi, and Toshiko Osada. "Experimental and Analytical Resin Impregnation Characterization in Carbon Fiber Reinforced Thermoplastic Composites." In JSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/lemp2020-8627.
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Abstract Effect of molding condition on resin impregnation behavior and the associated mechanical properties were investigated for carbon fabric reinforced thermoplastic composites. Carbon fiber yarn (TORAYCA, Toray) was used as a reinforcement, and thermoplastic PI (AURUM PL 450 C, Mitsui Chemicals) was used as the matrix. CFRTP textile composites were compression-molded with a hot press system under the molding temperature, 390 °C, 410 °C and 430 °C, molding pressure 2 MPa and 4 MPa and molding time 0∼300 s. In order to evaluate the impregnated state, cross sectional observation was performed with an optical microscope. Specimen cross-section was polished and finished with alumina slurry for a clear observation. The images observed were processed through image processing software to obtained impregnation ratio which defined as the resin impregnation area to the cross-sectional area of a fiber yarn. Resin impregnation was accelerated with molding temperature and pressure. At molding temperature more than 410 °C, resin impregnation was similar irrespective of temperature. Tensile test results indicated that modulus and strength increased with resin impregnation. Resin impregnation during molding was predicted using the analytical model based on Darcy’s law and continuity condition. The analysis could successfully predict the impregnation behavior despite the difference in molding pressure and temperature.
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Lee, Tae Hwa, Pei-Chung Wang, S. Jack Hu, and Mihaela Banu. "Investigation of the Dynamic Response of a Multispot System at Joining Using Ultrasonic Welding." In ASME 2021 16th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/msec2021-64916.
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Abstract Ultrasonic welding is one of the most practical joining method for polymer composite materials and has been adapted in the aerospace and automotive industries. To effectively join polymer composite assemblies, it is critical to understand the dynamic response of the welding system so that sound heating generation and welding sequences in the ultrasonic welding of the assemblies can be properly obtained. This study presents a dynamic response model of a multi-spot configuration assembly using ultrasonic welding. Here, a dynamic model of joining a U-shaped carbon fiber reinforced thermoplastic composite part with a flat part is developed and analyzed through the ratio between the frequencies generated at different locations of the spot with respect to the edges of the assembly and the natural frequency. Finally, this ratio is correlated with the weld quality of the multiple spot configuration. Guidelines for designing multisport sequence are extracted. This study provides a method to design the welding sequence in ultrasonic welding of carbon fiber reinforced composites.
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Stavrov, Darko, and Harald E. N. Bersee. "Thermal Aspects in Resistance Welding of Thermoplastic Composites." In ASME 2003 Heat Transfer Summer Conference. ASMEDC, 2003. http://dx.doi.org/10.1115/ht2003-47222.
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This paper presents a comprehensive experimental study on the thermal aspects in resistance welding of thermoplastic composites. A special test set-up was developed to perform the experiments. Glass fiber reinforced polyetherimide was the material used for manufacturing the welding specimens. Stainless steel mesh was used for production of heating elements. The temperature distribution was monitored using type-K thermocouples connected to a data acquisition system. The main objective of the study was investigating a possible solution for the edge effect. Temperature profiles over the weld length and over the weld width were monitored. The focus was on the transient temperature profiles at the edges of the weld. The temperature distribution through the weld thickness was also monitored. The influence of factors like insulation and power level was investigated. Finally, conclusions are drawn and options for improving the temperature distribution and modification of the models are being discussed.
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Qamar, Isabel P. S., and Richard S. Trask. "Development of Multi-Dimensional 3D Printed Vascular Networks for Self-Healing Materials." In ASME 2017 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/smasis2017-3829.
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Self-healing materials have emerged as an alternative solution to the repair of damage in fibre-reinforced composites. Recent developments have largely focused on a vascular approach, due to the ability to transport healing agents over long distances and continually replenish from an external source. However fracture of the vascular network is required to enable the healing agents to infiltrate the crack plane, ceasing its primary function in transporting fluid and preventing the repair of any further damage events. Here we present a novel approach to vascular self-healing through the development and integration of 3D printed, porous, thermoplastic networks into a thermoset matrix. This concept exploits the inherently low surface chemistry of thermoplastic materials, which results in adhesive failure between the thermoplastic network and thermoset matrix on arrival of a propagating crack, thus exposing the radial pores of the network and allowing the healing agents to flow into the damage site. We investigate the potential of two additive manufacturing techniques, fused deposition modeling (FDM) and stereolithography, to fabricate free-standing, self-healing networks. Furthermore, we assess the interaction of a crack with branched network structures under static indentation in order to establish the feasibility of additive manufacture for multi-dimensional 3D printed self-healing networks.
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Rangisetty, Sridher, and Larry D. Peel. "The Effect of Infill Patterns and Annealing on Mechanical Properties of Additively Manufactured Thermoplastic Composites." In ASME 2017 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/smasis2017-4011.
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Recently, carbon fiber-reinforced thermoplastics (CFRTPs) have become popular choices in desktop-based additive manufacturing, but there is limited information on their effective usage. In Fused Deposition Modeling (FDM), a structure is created by layers of extruded beads. The degree of bonding between beads, bead orientation, degree of interlayer bonding, type of infill and the type of material, determines overall mechanical performance. The presence of chopped fibers in thermoplastics increases melt viscosity, changes coefficients of thermal expansion, may have layer adhesion issues, and causes increased wear on nozzles, which makes FDM fabrication of thermoplastic composites somewhat different from neat thermoplastics. In the current work, best practices and the effect of annealing and infill patterns on the mechanical performance of FDM-fabricated composite parts were investigated. Materials included commercially available PLA, CF-PLA, ABS, CF-ABS, PETG, and CF-PETG. Two sets of ASTM D638 tensile and ASTM D790 flexural test specimens with 3 different infill patterns and each material were fabricated, one set annealed, and all tested. Anisotropic behavior was observed as a function of infill pattern. As expected, strength and stiffness were higher when the beads were oriented in the direction of the load, even for neat resins. All fiber-filled tensile results showed an increase in stiffness, but surprisingly, not in strength (likely due to very short fiber lengths). Tests of annealed specimens resulted in clear improvements in tensile strength, tensile stiffness and flexural strength for PLA, CF-PLA, and PETG, CF-PETG but a reduction in flexural stiffness. Also, annealing resulted in mixed improvements for ABS and CF-ABS and is only useful in certain infill patterns. This work also establishes ‘Best Practices’ of FDM-type fabrication of thermoplastic composite structures and documents the minimum critical fiber lengths and fiber fractions of several CF-filled FDM filaments.
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Garate, Juan, Stephen A. Solovitz, and Dave Kim. "A Preliminary Study on Small Thermoplastic Composite Wind Turbine Blade Design and Fabrication." In ASME 2015 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2015. http://dx.doi.org/10.1115/imece2015-51745.
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Today a large-scale wind turbine blade can be 70 m long and 5 m in root chord length, and it is fabricated in a single piece. This feature leads to high initial costs, as transportation of a large blade requires special trucks, escorts, and road adaptations. These constraints can account for approximately 6–7% of the total investment for the blade. In addition, the manufacturing process commonly used is a hand lay-up configuration of thermoset composite sheets. These materials are not reusable after fabrication, which is a non-renewable feature of existing systems. The project consists of manufacturing thermoplastic composite blades in segments, which are joined before installation at the turbine site. This paper addresses the preliminary research results when conducting design and fabrication of a small blade with this innovative approach. Three segmented blades are manufactured for a horizontal-axis wind turbine, with each blade having a 50 cm span and a 4 cm tip chord length. The blade size and profile are designed based on the idealized Betz limit condition. The material used for manufacturing is a glass fiber reinforced thermoplastic composite system with a polypropylene matrix that melts at 200 °C. Each blade is fabricated in 4 independently manufactured pieces, consisting of top/bottom, and tip/root segments, via a vacuum assisted thermoforming technique. The parts will be assembled afterwards by a joining process, forming the final part for site testing.