Pub Date : 2016-01-02DOI: 10.1080/20550340.2016.1141457
M. Rouhi, M. Wysocki, R. Larsson
Abstract In the present paper, we present a novel finite-element method capable of handling most of the physics arising in the resin wet-out step for any composite system and processing case. The method is based on a compressible two-phase continuum formulation where a key feature is to model the involved physics via innovative use of the compressibility of the phases. On the one hand, the fluid-phase compressibility is used to capture the physics of the advancing resin front as well as the physics behind the flow front. On the other hand, solid-phase compressibility is used to model micro-infiltration of the resin and the corresponding preform compaction, essentially considered as a fluid sink problem. Finally, the generic porous media model is formulated in the finite strain regime. The model is implemented and demonstrated for different manufacturing methods and the results with respect to each example are presented. The degree of saturation, pressure distribution, preform deformation, and reaction forces are some of the post-processed results for different manufacturing methods. The ultimate goal of this contribution is to establish a unified generic and general simulation tool for structural (long fiber) composite processing where, to this date, there is no single FE-based tool available commercially for this purpose.
{"title":"Holistic modeling of composites manufacturing using poromechanics","authors":"M. Rouhi, M. Wysocki, R. Larsson","doi":"10.1080/20550340.2016.1141457","DOIUrl":"https://doi.org/10.1080/20550340.2016.1141457","url":null,"abstract":"Abstract In the present paper, we present a novel finite-element method capable of handling most of the physics arising in the resin wet-out step for any composite system and processing case. The method is based on a compressible two-phase continuum formulation where a key feature is to model the involved physics via innovative use of the compressibility of the phases. On the one hand, the fluid-phase compressibility is used to capture the physics of the advancing resin front as well as the physics behind the flow front. On the other hand, solid-phase compressibility is used to model micro-infiltration of the resin and the corresponding preform compaction, essentially considered as a fluid sink problem. Finally, the generic porous media model is formulated in the finite strain regime. The model is implemented and demonstrated for different manufacturing methods and the results with respect to each example are presented. The degree of saturation, pressure distribution, preform deformation, and reaction forces are some of the post-processed results for different manufacturing methods. The ultimate goal of this contribution is to establish a unified generic and general simulation tool for structural (long fiber) composite processing where, to this date, there is no single FE-based tool available commercially for this purpose.","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2016-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"82093651","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2016-01-02DOI: 10.1080/20550340.2016.1182783
D. Becker, H. Grössing, S. Konstantopoulos, E. Fauster, P. Mitschang, R. Schledjewski
Abstract Research concerning the measurement of the permeability of fabrics for polymer matrix composites has been ongoing since several decades, but remains in the focus of applied research for liquid composite molding. Today, several systems and technologies for the measurement of in- and out-of-plane permeability are available, but still no approach has gained acceptance as a common standard. A main requirement for reliable permeability measurement technology is the reproducibility of results when comparing different characterization systems. In this context, benchmark studies are an appropriate method to evaluate the reproducibility of a technology. This study presents a benchmark on unsaturated out-of-plane permeability measurement systems based on flow front monitoring via ultrasonic sensors. Two corresponding systems are compared in the study comprising carbon and glass wovens as well as non-crimp fabrics. The out-of-plane permeability was measured with both systems at three different levels of fiber volume content and three repetitive measurements. The results gained with the systems showed good compliance with relative deviation of the permeability values mostly below 50%. Textile-induced inhomogeneities and varying measurement parameters, e.g. injection pressure, were found to be main reasons for the deviations.
{"title":"An evaluation of the reproducibility of ultrasonic sensor-based out-of-plane permeability measurements: a benchmarking study","authors":"D. Becker, H. Grössing, S. Konstantopoulos, E. Fauster, P. Mitschang, R. Schledjewski","doi":"10.1080/20550340.2016.1182783","DOIUrl":"https://doi.org/10.1080/20550340.2016.1182783","url":null,"abstract":"Abstract Research concerning the measurement of the permeability of fabrics for polymer matrix composites has been ongoing since several decades, but remains in the focus of applied research for liquid composite molding. Today, several systems and technologies for the measurement of in- and out-of-plane permeability are available, but still no approach has gained acceptance as a common standard. A main requirement for reliable permeability measurement technology is the reproducibility of results when comparing different characterization systems. In this context, benchmark studies are an appropriate method to evaluate the reproducibility of a technology. This study presents a benchmark on unsaturated out-of-plane permeability measurement systems based on flow front monitoring via ultrasonic sensors. Two corresponding systems are compared in the study comprising carbon and glass wovens as well as non-crimp fabrics. The out-of-plane permeability was measured with both systems at three different levels of fiber volume content and three repetitive measurements. The results gained with the systems showed good compliance with relative deviation of the permeability values mostly below 50%. Textile-induced inhomogeneities and varying measurement parameters, e.g. injection pressure, were found to be main reasons for the deviations.","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2016-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75818255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2016-01-02DOI: 10.1080/20550340.2016.1165439
G. Gong, Kurt S. Olofsson, B. Nyström, M. Juntikka, Henrik Oxfall, K. Lindqvist
Abstract A new concept, Re-Fib, was developed within an EU project, REFORM, to recycle carbon and glass fibres from polymeric composite structures, aiming to reduce energy consumption and degradation of fibre properties during recycling. The optimized thermolysis treatment, 24 h at 380 °C, was verified able to recover clean fibres from most tested composite structures containing different thermoset resins (epoxy, vinyl ester, and polyester) and various core materials such as polyvinyl chloride (PVC), polyurethane (PU), and wood. Single-fibre test was performed in dynamic mechanical analysis (DMA). The reduction of strength was found around 26% for carbon fibres and 34–40% for glass fibres. Thermally recycled glass fibres were melt-compounded with recycled polypropylene (rPP); the resultant composites showed promising mechanical properties.
{"title":"Experimental verification of Re-Fib method for recycling fibres from composites","authors":"G. Gong, Kurt S. Olofsson, B. Nyström, M. Juntikka, Henrik Oxfall, K. Lindqvist","doi":"10.1080/20550340.2016.1165439","DOIUrl":"https://doi.org/10.1080/20550340.2016.1165439","url":null,"abstract":"Abstract A new concept, Re-Fib, was developed within an EU project, REFORM, to recycle carbon and glass fibres from polymeric composite structures, aiming to reduce energy consumption and degradation of fibre properties during recycling. The optimized thermolysis treatment, 24 h at 380 °C, was verified able to recover clean fibres from most tested composite structures containing different thermoset resins (epoxy, vinyl ester, and polyester) and various core materials such as polyvinyl chloride (PVC), polyurethane (PU), and wood. Single-fibre test was performed in dynamic mechanical analysis (DMA). The reduction of strength was found around 26% for carbon fibres and 34–40% for glass fibres. Thermally recycled glass fibres were melt-compounded with recycled polypropylene (rPP); the resultant composites showed promising mechanical properties.","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2016-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"79181670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2016-01-02DOI: 10.1080/20550340.2016.1154642
Christian Hueber, K. Horejsi, Ralf Schledjewski
Abstract This review aims to provide an overview to the extensive field of cost estimation for aerospace composite production, describing the basic methods of how to perform cost estimation and introducing some of the existing models. While some might claim for more existing estimation methods this review, however, recommends the classification into only the three primary methods: analogous, parametric, and bottom-up cost estimation. Furthermore, a selection of the existing cost estimation models for the aerospace composite manufacturing will also be presented and detailed here in this paper. Models are considered to be structures embedding one more of the basic estimation methods in an attempt to enhance or combine their different strengths. This paper also focuses on some of the main issues encountered when engaging in cost estimation.
{"title":"Review of cost estimation: methods and models for aerospace composite manufacturing","authors":"Christian Hueber, K. Horejsi, Ralf Schledjewski","doi":"10.1080/20550340.2016.1154642","DOIUrl":"https://doi.org/10.1080/20550340.2016.1154642","url":null,"abstract":"Abstract This review aims to provide an overview to the extensive field of cost estimation for aerospace composite production, describing the basic methods of how to perform cost estimation and introducing some of the existing models. While some might claim for more existing estimation methods this review, however, recommends the classification into only the three primary methods: analogous, parametric, and bottom-up cost estimation. Furthermore, a selection of the existing cost estimation models for the aerospace composite manufacturing will also be presented and detailed here in this paper. Models are considered to be structures embedding one more of the basic estimation methods in an attempt to enhance or combine their different strengths. This paper also focuses on some of the main issues encountered when engaging in cost estimation.","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2016-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"79441787","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2015-10-02DOI: 10.1080/20550340.2015.1105613
H. Jones, A. Chatzimichali, R. Middleton, K. Potter, C. Ward
Abstract This research investigates the handheld and often personally owned tools used by laminators to form advanced composites into components for aerospace, defense, and autosport; and reports on the application of a novel concept. The lack of formal knowledge that surrounds the existence and use of these tools presents an opportunity to explore what significance they have for process standardization and composites’ design and manufacture. The paper presents results from layup trials that were performed to test a prototyped tool, designed with user-centered and geometry-driven research in mind. The trials showed tool use is aligned with the laminator’s goals for the layup task; and suggest that it is also used as the laminator’s method for reporting quality feedback. The trials also raised questions about why the laminators habitually use their tools and the necessity of supporting a laminator through the decision processes involved in a layup task. This suggests the development of a prototyped tool can be of significant benefit in the realm of skills and training. Graphical abstract
{"title":"Exploring the discrete tools used by laminators in composites manufacturing: application of novel concept","authors":"H. Jones, A. Chatzimichali, R. Middleton, K. Potter, C. Ward","doi":"10.1080/20550340.2015.1105613","DOIUrl":"https://doi.org/10.1080/20550340.2015.1105613","url":null,"abstract":"Abstract This research investigates the handheld and often personally owned tools used by laminators to form advanced composites into components for aerospace, defense, and autosport; and reports on the application of a novel concept. The lack of formal knowledge that surrounds the existence and use of these tools presents an opportunity to explore what significance they have for process standardization and composites’ design and manufacture. The paper presents results from layup trials that were performed to test a prototyped tool, designed with user-centered and geometry-driven research in mind. The trials showed tool use is aligned with the laminator’s goals for the layup task; and suggest that it is also used as the laminator’s method for reporting quality feedback. The trials also raised questions about why the laminators habitually use their tools and the necessity of supporting a laminator through the decision processes involved in a layup task. This suggests the development of a prototyped tool can be of significant benefit in the realm of skills and training. Graphical abstract","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"81933976","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2015-10-02DOI: 10.1080/20550340.2015.1117747
F. Islam, J. Ramkumar, A. S. Milani
Abstract This article presents a simple framework for predicting the occurrence of delamination during milling of unidirectional carbon-fiber-reinforced plastics (CFRPs), based on a concept of effective critical cutting zone. To validate the concept, sets of milling experiments were conducted on unidirectional CFRP samples of varying fiber orientations and the delamination signature was measured through microscopic images. By observing the damage extent for different fiber orientation angles and different fiber cutting angles for up-milled and down-milled edges, and correlating them with different material removal mechanisms, it has been shown that the damage mainly depends on the portion of the fiber cutting angles that lie within the effective critical milling zone. Both the delamination and the normal cutting forces were found to be strongly dependent on the range of angles in this zone. In addition, it is shown that the cutting force may be used as a good approximation to determine the effect of machining/process parameters on the ensuing delamination damage during milling of CFRPs. For the tested samples, the normal cutting force decreased with an increase in the cutting speed and it increased with an increase in the feed rate of the cutting tool.
{"title":"A simplified damage prediction framework for milling of unidirectional carbon fiber-reinforced plastics","authors":"F. Islam, J. Ramkumar, A. S. Milani","doi":"10.1080/20550340.2015.1117747","DOIUrl":"https://doi.org/10.1080/20550340.2015.1117747","url":null,"abstract":"Abstract This article presents a simple framework for predicting the occurrence of delamination during milling of unidirectional carbon-fiber-reinforced plastics (CFRPs), based on a concept of effective critical cutting zone. To validate the concept, sets of milling experiments were conducted on unidirectional CFRP samples of varying fiber orientations and the delamination signature was measured through microscopic images. By observing the damage extent for different fiber orientation angles and different fiber cutting angles for up-milled and down-milled edges, and correlating them with different material removal mechanisms, it has been shown that the damage mainly depends on the portion of the fiber cutting angles that lie within the effective critical milling zone. Both the delamination and the normal cutting forces were found to be strongly dependent on the range of angles in this zone. In addition, it is shown that the cutting force may be used as a good approximation to determine the effect of machining/process parameters on the ensuing delamination damage during milling of CFRPs. For the tested samples, the normal cutting force decreased with an increase in the cutting speed and it increased with an increase in the feed rate of the cutting tool.","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90243196","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2015-10-02DOI: 10.1080/20550340.2015.1117748
N. Brown, C. Worrall, S. Ogin, P. Smith
Abstract A thermally assisted piercing (TAP) process has been investigated as an alternative to current methods of machining holes in thermoplastic composites. The spike force/displacement responses during piercing were affected by both the processing temperature and the size of the heated area, as were the resultant microstructure and subsequent mechanical performance. Overall, the results suggest that for advanced manufacturing of thermoplastic composites, good tensile and compressive open-hole properties are produced in the TAP process when using small heated areas and higher temperatures.
{"title":"Investigation into the mechanical properties of thermoplastic composites containing holes machined by a thermally-assisted piercing (TAP) process","authors":"N. Brown, C. Worrall, S. Ogin, P. Smith","doi":"10.1080/20550340.2015.1117748","DOIUrl":"https://doi.org/10.1080/20550340.2015.1117748","url":null,"abstract":"Abstract A thermally assisted piercing (TAP) process has been investigated as an alternative to current methods of machining holes in thermoplastic composites. The spike force/displacement responses during piercing were affected by both the processing temperature and the size of the heated area, as were the resultant microstructure and subsequent mechanical performance. Overall, the results suggest that for advanced manufacturing of thermoplastic composites, good tensile and compressive open-hole properties are produced in the TAP process when using small heated areas and higher temperatures.","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"87947450","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2015-07-03DOI: 10.1080/20550340.2015.1114801
M. Elkington, D. Bloom, C. Ward, A. Chatzimichali, K. Potter
The hand layup of pre-impregnated woven materials is still a large part of the composite manufacturing industry, requiring the skills and experience of a human workforce to form flat plies into complex shapes. It is capable of producing high performance and complex parts, but can be an expensive and variable process. Despite its importance, there appears to have been very little research into the actual methods and techniques used by workers to manipulate flat sheets of composite material into shape during layup. This work presents the first known detailed study of the approach and techniques used by laminators. Four participants laid up onto 15 different shaped molds that replicated features commonly found on composite components. The actions used in layup were grouped into eight distinct techniques. Use of these techniques across tasks of different geometry, ramp angles, radii and drape path was identified using video analysis techniques from the ergonomics field. This revealed strong links between specific features and techniques, revealing a systematic approach to layup. This has enabled the first step toward producing a design for manufacture knowledge base surrounding hand layup. This could then be used to inform the development of the layup process, improve training methods and assist in the design of future automated solutions. Graphical Abstract
{"title":"Hand layup: understanding the manual process","authors":"M. Elkington, D. Bloom, C. Ward, A. Chatzimichali, K. Potter","doi":"10.1080/20550340.2015.1114801","DOIUrl":"https://doi.org/10.1080/20550340.2015.1114801","url":null,"abstract":"The hand layup of pre-impregnated woven materials is still a large part of the composite manufacturing industry, requiring the skills and experience of a human workforce to form flat plies into complex shapes. It is capable of producing high performance and complex parts, but can be an expensive and variable process. Despite its importance, there appears to have been very little research into the actual methods and techniques used by workers to manipulate flat sheets of composite material into shape during layup. This work presents the first known detailed study of the approach and techniques used by laminators. Four participants laid up onto 15 different shaped molds that replicated features commonly found on composite components. The actions used in layup were grouped into eight distinct techniques. Use of these techniques across tasks of different geometry, ramp angles, radii and drape path was identified using video analysis techniques from the ergonomics field. This revealed strong links between specific features and techniques, revealing a systematic approach to layup. This has enabled the first step toward producing a design for manufacture knowledge base surrounding hand layup. This could then be used to inform the development of the layup process, improve training methods and assist in the design of future automated solutions. Graphical Abstract","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86629866","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2015-07-03DOI: 10.1080/20550340.2015.1114797
Hugo Aimé, S. Comas-Cardona, C. Binetruy, J. Schell, M. Lacrampe, M. Deléglise-Lagardère
The construction of mesoscopic models of fiber washing effects during the high pressure resin transfer molding (RTM) process with thermoplastic polymers requires the knowledge of the limit of adhesion coefficients between dry and impregnated fabric reinforcement plies and the mold. To measure these coefficients, a new method is described. During RTM process, a preform is placed in the cavity. The mold is closed to reach a given cavity thickness. Therefore, the normal stress applied to the preform can be relaxed before injection. In order to comply with these RTM specificities, the limit of adhesion coefficients are measured on relaxed preforms at given thicknesses. Hence, a first set of compression tests followed by a relaxation step are performed in order to measure the normal stresses the preforms undergo. The relaxation can reduce compression normal stress by 30%. The relaxation is taken into account for the limit of adhesion calculation. Then a second setup has been built in order to measure forces during pull-out of fabric plies inserted between other plies or metallic plates. This method provides mean values of coefficients of limit of adhesion for dry and lubricated preforms and various stacking sequences. These coefficients can be refined so as to take into account the real area of the contact interface for ply/ply and ply/mold configurations. There are also useful in the forming process of dry fabrics when inter-ply sliding occurs. Graphical Abstract
{"title":"Limit of adhesion coefficient measurement of a unidirectional carbon fabric","authors":"Hugo Aimé, S. Comas-Cardona, C. Binetruy, J. Schell, M. Lacrampe, M. Deléglise-Lagardère","doi":"10.1080/20550340.2015.1114797","DOIUrl":"https://doi.org/10.1080/20550340.2015.1114797","url":null,"abstract":"The construction of mesoscopic models of fiber washing effects during the high pressure resin transfer molding (RTM) process with thermoplastic polymers requires the knowledge of the limit of adhesion coefficients between dry and impregnated fabric reinforcement plies and the mold. To measure these coefficients, a new method is described. During RTM process, a preform is placed in the cavity. The mold is closed to reach a given cavity thickness. Therefore, the normal stress applied to the preform can be relaxed before injection. In order to comply with these RTM specificities, the limit of adhesion coefficients are measured on relaxed preforms at given thicknesses. Hence, a first set of compression tests followed by a relaxation step are performed in order to measure the normal stresses the preforms undergo. The relaxation can reduce compression normal stress by 30%. The relaxation is taken into account for the limit of adhesion calculation. Then a second setup has been built in order to measure forces during pull-out of fabric plies inserted between other plies or metallic plates. This method provides mean values of coefficients of limit of adhesion for dry and lubricated preforms and various stacking sequences. These coefficients can be refined so as to take into account the real area of the contact interface for ply/ply and ply/mold configurations. There are also useful in the forming process of dry fabrics when inter-ply sliding occurs. Graphical Abstract","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86155533","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2015-07-03DOI: 10.1080/20550340.2015.1114798
D. Maurer, P. Mitschang
The laser-assisted thermoplastic tape placement process for unidirectional carbon fiber reinforced polyetheretherketon (CF PEEK) tapes was investigated. In this process, tapes are melted, laid-up on a tool, and consolidated under a roller. As an out of autoclave process, thermoplastic tape placement has high potential for aerospace manufacturing industry. To optimize laser settings for high efficiency and reproducibility, a thermal simulation was created. Process windows are calculated based on critical process temperatures. A parameter study was conducted to investigate the influence of lay-up speed and laser settings, especially laser beam height and angle of impact, on the process. For different lay-up speeds, optimum values and limits of laser settings are found to gain autoclave quality with high material output and high reproducibility. Peel specimens have been produced to verify simulated optimum parameters, which showed good agreement. Economical potential of thermoplastic tape placement was shown in a direct comparison to thermoset tape placement. Graphical Abstract
{"title":"Laser-powered tape placement process – simulation and optimization","authors":"D. Maurer, P. Mitschang","doi":"10.1080/20550340.2015.1114798","DOIUrl":"https://doi.org/10.1080/20550340.2015.1114798","url":null,"abstract":"The laser-assisted thermoplastic tape placement process for unidirectional carbon fiber reinforced polyetheretherketon (CF PEEK) tapes was investigated. In this process, tapes are melted, laid-up on a tool, and consolidated under a roller. As an out of autoclave process, thermoplastic tape placement has high potential for aerospace manufacturing industry. To optimize laser settings for high efficiency and reproducibility, a thermal simulation was created. Process windows are calculated based on critical process temperatures. A parameter study was conducted to investigate the influence of lay-up speed and laser settings, especially laser beam height and angle of impact, on the process. For different lay-up speeds, optimum values and limits of laser settings are found to gain autoclave quality with high material output and high reproducibility. Peel specimens have been produced to verify simulated optimum parameters, which showed good agreement. Economical potential of thermoplastic tape placement was shown in a direct comparison to thermoset tape placement. Graphical Abstract","PeriodicalId":7243,"journal":{"name":"Advanced Manufacturing: Polymer & Composites Science","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2015-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"83774565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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