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A Guide to Modeling Thermoplastic Composite Manufacturing Processes

Optimizing Process Variables and Tooling Design Using Finite Element Analysis

Corey Lynam, P. Eng., Master of Applied Science, Mechanical Engineering, University of British Columbia
Abbas S. Milani, P. Eng., Ph.D., Associate Professor, Mechanical Engineering, University of British Columbia

 

ISBN: 978-1-60595-042-6, ©2015, 100 pages, 6×9, Soft cover

  • Models and experiments for faster, less expensive manufacture of thermoplastic parts
  • Focused on simulating thermal defects in thermoplastics
  • Techniques for better molds, tooling and equipment

Book explains methods and coding to create FEM-based models to optimize process variables and predict dimensional distortions during the manufacture of thermoplastic matrix composite parts. After investigating defects, such as spring-in, caused by thermal inconsistencies during manufacture, the text offers a step-by-step approach to simulating and predicting the magnitude of distortion via readily available FE codes. Models are validated by testing using the example of a multi-staged roll-formed continuous thermoplastic woven laminate, which can be readily extended to a variety of mold geometries. Information in this book is intended to reduce the need for costly and time-consuming re-tooling in thermoplastic parts design.

Preface

1. Introduction

2. Background
2.1. Thermoplastic Matrix Composite Materials
2.1.1. Twintex®
2.1.2. Crystallization in Polypropylene
2.2. Thermoplastic Matrix Composite Manufacturing Methods
2.2.1. Compression Moulding
2.2.2. Vacuum Bag and Autoclave
2.2.3. Roll Forming
2.2.4. Stamp Forming
2.3. Spring-in
2.3.1. Spring-in Mechanisms

3. Synopsis of Current Knowledge
3.1. Thermoplastic Spring-in Modeling

4. Material Property Testing
4.1. Uniaxial Extension
4.2. Thermal Mechanical Analysis (TMA)
4.3. Differential Scanning Calorimetry (DSC)
4.4. Dynamic Mechanical Analysis (DMA)
4.5. Stress Relaxation

5. Process Characterization of Roll Forming
5.1. Geometry of Example Case
5.2. Thermal Cycle
5.3. Spring-in Measurements

6. Case Study Modeling Approaches and Results
6.1. Analysis Type
6.2. Model 1: Using Elastic Mechanical Properties
6.2.1. Geometry
6.2.2. Material Properties
6.2.3. Boundary Conditions
6.2.4. Analysis Steps
6.2.5. Mesh
6.2.6. Results
6.2.7. Sensitivity Analysis
6.2.8. Summary
6.3. Model 2: Using Viscoelastic Mechanical Properties
6.3.1. Material Properties
6.3.2. Results and Discussion
6.4. Model 3: Pseudo Meso-Level Decomposition
6.4.1. Results and Discussion

7. Conclusions and Recommendations

Bibliography
Index

A Guide to Modeling Thermoplastic Composite Manufacturing Processes (Entire eBook)
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Chapter 1: Introduction
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Chapter 2: Background
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Chapter 3: Synopsis of Current Knowledge
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Chapter 4: Material Property Testing
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Chapter 5: Process Characterization of Roll Forming
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Chapter 6: Case Study Modeling Approaches and Results
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Chapter 7: Conclusions and Recommendations
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ISBN: 978-1-60595-042-6, ©2015, 100 pages, 6×9, Soft cover

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