Process modeling in composites manufacturing

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010058889	TA418.9.C6 A384 2003	Open Access Book	Book	Searching... Unknown
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There is a wealth of literature on modeling and simulation of polymer composite manufacturing processes. However, existing books neglect to provide a systematic explanation of how to formulate and apply science-based models in polymer composite manufacturing processes. Process Modeling in Composites Manufacturing, Second Editionprovides tangible methods to optimize this process -- and it remains a proven, powerful introduction to the basic principles of fluid mechanics and heat transfer.

Includes tools to develop an experience base to aid in modeling a composite manufacturing process

Building on past developments, this new book updates the previous edition's coverage of process physics and the state of modeling in the field. Exploring research derived from experience, intuition, and trial and error, the authors illustrate a state-of-the-art understanding of mass, momentum, and energy transfer during composites processing. They introduce computer-based solutions using MATLAB® code and flow simulation-based analysis, which complement closed-form solutions discussed in the book, to help readers understand the role of different material, geometric, and process parameters.

This self-contained primer provides an introduction to modeling of composite manufacturing processes for anyone working in material science and engineering, industrial, mechanical, and chemical engineering. It introduces a scientific basis for manufacturing, using solved example problems which employ calculations provided in the book. End-of-chapter questions and problems and fill in the blanks sections reinforce the content in order to develop the experience base of the manufacturing, materials, and design engineer or scientists, as well as seniors and first-year graduate students.

Author Notes

Suresh G. Advani is Associate Director, Center for Composite Materials, and Professor of Mechanical Engineering, University of Delaware, Newark
E. Murat Sozer is Assistant Professor of Mechanical Engineering, Koc University, Istanbul, Turkey

Preface	p. iii
1 Introduction	p. 1
1.1 Motivation and Contents	p. 1
1.2 Preliminaries	p. 2
1.3 Polymer Matrices for Composites	p. 4
1.3.1 Polymer Resins	p. 7
1.3.2 Comparison Between Thermoplastic and Thermoset Polymers	p. 9
1.3.3 Additives and Inert Fillers	p. 11
1.4 Fibers	p. 11
1.4.1 Fiber-Matrix Interface	p. 12
1.5 Classification	p. 13
1.5.1 Short Fiber Composites	p. 13
1.5.2 Advanced Composites	p. 15
1.6 General Approach to Modeling	p. 16
1.7 Organization of the Book	p. 18
1.8 Exercises	p. 18
1.8.1 Questions	p. 18
1.8.2 Fill in the Blanks	p. 19
2 Overview of Manufacturing Processes	p. 23
2.1 Background	p. 23
2.2 Classification Based on Dominant Flow Process	p. 24
2.3 Short Fiber Suspension Manufacturing Methods	p. 25
2.3.1 Injection Molding	p. 25
2.3.2 Extrusion	p. 32
2.3.3 Compression Molding	p. 34
2.4 Advanced Thermoplastic Manufacturing Methods	p. 37
2.4.1 Sheet Forming	p. 38
2.4.2 Thermoplastic Pultrusion	p. 41
2.4.3 Thermoplastic Tape Lay-Up Process	p. 44
2.5 Advanced Thermoset Composite Manufacturing Methods	p. 46
2.5.1 Autoclave Processing	p. 46
2.5.2 Liquid Composite Molding	p. 49
2.5.3 Filament Winding	p. 52
2.6 Exercises	p. 54
2.6.1 Questions	p. 54
2.6.2 Fill in the Blanks	p. 58
3 Transport Equations for Composite Processing	p. 63
3.1 Introduction to Process Models	p. 63
3.2 Conservation of Mass (Continuity Equation)	p. 64
3.2.1 Conservation of Mass	p. 65
3.2.2 Mass Conservation for Resin with Presence of Fiber	p. 69
3.3 Conservation of Momentum (Equation of Motion)	p. 70
3.4 Stress-Strain Rate Relationship	p. 75
3.4.1 Kinematics of Fluid	p. 75
3.4.2 Newtonian Fluids	p. 80
3.5 Examples on Use of Conservation Equations to Solve Viscous Flow Problems	p. 84
3.5.1 Boundary Conditions	p. 84
3.5.2 Solution Procedure	p. 87
3.6 Conservation of Energy	p. 95
3.6.1 Heat Flux-Temperature Gradient Relationship	p. 101
3.6.2 Thermal Boundary Conditions	p. 103
3.7 Exercises	p. 107
3.7.1 Questions	p. 107
3.7.2 Problems	p. 108
4 Constitutive Laws and Their Characterization	p. 111
4.1 Introduction	p. 111
4.2 Resin Viscosity	p. 112
4.2.1 Shear Rate Dependence	p. 114
4.2.2 Temperature and Cure Dependence	p. 118
4.3 Viscosity of Aligned Fiber Thermoplastic Laminates	p. 121
4.4 Suspension Viscosity	p. 129
4.4.1 Regimes of Fiber Suspension	p. 129
4.4.2 Constitutive Equations	p. 136
4.5 Reaction Kinetics	p. 137
4.5.1 Techniques to Monitor Cure: Macroscopic Characterization	p. 141
4.5.2 Technique to Monitor Cure: Microscopic Characterization	p. 143
4.5.3 Effect of Reinforcements on Cure Kinetics	p. 144
4.6 Crystallization Kinetics	p. 146
4.6.1 Introduction	p. 146
4.6.2 Solidification and Crystallization	p. 146
4.6.3 Background	p. 147
4.6.4 Crystalline Structure	p. 148
4.6.5 Spherulitic Growth	p. 149
4.6.6 Macroscopic Crystallization	p. 150
4.7 Permeability	p. 151
4.7.1 Permeability and Preform Parameters	p. 155
4.7.2 Analytic and Numerical Characterization of Permeability	p. 156
4.7.3 Experimental Characterization of Permeability	p. 157
4.8 Fiber Stress	p. 161
4.9 Exercises	p. 164
4.9.1 Questions	p. 164
4.9.2 Fill in the Blanks	p. 167
4.9.3 Problems	p. 169
5 Model Simplifications and Solution	p. 173
5.1 Introduction	p. 173
5.1.1 Usefulness of Models	p. 174
5.2 Formulation of Models	p. 175
5.2.1 Problem Definition	p. 175
5.2.2 Building the Mathematical Model	p. 177
5.2.3 Solution of the Equations	p. 177
5.2.4 Model Assessment	p. 178
5.2.5 Revisions of the Model	p. 179
5.3 Model and Geometry Simplifications	p. 180
5.4 Dimensionless Analysis and Dimensionless Numbers	p. 183
5.4.1 Dimensionless Numbers Used in Composites Processing	p. 190
5.5 Customary Assumptions in Polymer Composite Processing	p. 198
5.5.1 Quasi-Steady State	p. 198
5.5.2 Fully Developed Region and Entrance Effects	p. 199
5.5.3 Lubrication Approximation	p. 200
5.5.4 Thin Shell Approximation	p. 201
5.6 Boundary Conditions for Flow Analysis	p. 201
5.6.1 In Contact with the Solid Surface	p. 201
5.6.2 In Contact with Other Fluid Surfaces	p. 202
5.6.3 Free Surfaces	p. 202
5.6.4 No Flow out of the Solid Surface	p. 202
5.6.5 Specified Conditions	p. 203
5.6.6 Periodic Boundary Condition	p. 203
5.6.7 Temperature Boundary Conditions	p. 203
5.7 Convection of Variables	p. 205
5.8 Process Models from Simplified Geometries	p. 206
5.8.1 Model Construction Based on Simple Geometries	p. 209
5.9 Mathematical Tools for Simplification	p. 211
5.9.1 Transformation of Coordinates	p. 211
5.9.2 Superposition	p. 213
5.9.3 Decoupling of Equations	p. 215
5.10 Solution Methods	p. 216
5.10.1 Closed Form Solutions	p. 217
5.11 Numerical Methods	p. 219
5.12 Validation	p. 221
5.12.1 Various Approaches for Validation	p. 221
5.13 Exercises	p. 223
5.13.1 Questions	p. 223
5.13.2 Problems	p. 225
6 Short Fiber Composites	p. 227
6.1 Introduction	p. 227
6.2 Compression Molding	p. 229
6.2.1 Basic Processing Steps [1]	p. 229
6.2.2 Applications [1]	p. 230
6.2.3 Flow Modeling	p. 231
6.2.4 Thin Cavity Models	p. 231
6.2.5 Hele-Shaw Model	p. 234
6.2.6 Lubricated Squeeze Flow Model	p. 238
6.2.7 Hele-Shaw Model with a Partial Slip Boundary Condition [2]	p. 243
6.2.8 Heat Transfer and Cure	p. 248
6.2.9 Cure	p. 251
6.2.10 Coupling of Heat Transfer with Cure	p. 252
6.2.11 Fiber Orientation	p. 254
6.3 Extrusion	p. 255
6.3.1 Flow Modeling	p. 257
6.3.2 Calculation of Power Requirements [3]	p. 260
6.3.3 Variable Channel Length [3]	p. 262
6.3.4 Newtonian Adiabatic Analysis [3]	p. 263
6.4 Injection Molding	p. 265
6.4.1 Process Description	p. 265
6.4.2 Materials	p. 267
6.4.3 Applications	p. 267
6.4.4 Critical Issues	p. 268
6.4.5 Model Formulation for Injection Molding	p. 269
6.4.6 Fiber Orientation	p. 280
6.5 Exercises	p. 285
6.5.1 Questions	p. 285
6.5.2 Fill in the Blanks	p. 287
6.5.3 Problems	p. 289
7 Advanced Thermoplastic Composite Manufacturing Processes	p. 291
7.1 Introduction	p. 291
7.2 Composite Sheet Forming Processes	p. 292
7.2.1 Diaphragm Forming	p. 293
7.2.2 Matched Die Forming	p. 293
7.2.3 Stretch and Roll Forming	p. 295
7.2.4 Deformation Mechanisms	p. 296
7.3 Pultrusion	p. 299
7.3.1 Thermoset Versus Thermoplastics Pultrusion	p. 300
7.3.2 Cell Model [4]	p. 300
7.4 Thermal Model	p. 308
7.4.1 Transient Heat Transfer Equation	p. 308
7.4.2 Viscous Dissipation	p. 310
7.5 On-line Consolidation of Thermoplastics	p. 311
7.5.1 Introduction to Consolidation Model	p. 314
7.5.2 Importance of Process Modeling	p. 314
7.5.3 Consolidation Process Model	p. 316
7.5.4 Model Assumptions and Simplifications	p. 316
7.5.5 Governing Equations	p. 317
7.5.6 Boundary Conditions	p. 322
7.5.7 Rheology of the Composite	p. 323
7.5.8 Model Solutions	p. 324
7.5.9 Inverse Problem of Force Control	p. 331
7.5.10 Extended Consolidation Model	p. 331
7.6 Exercises	p. 333
7.6.1 Questions	p. 333
7.6.2 Fill in the Blanks	p. 334
7.6.3 Problems	p. 337
8 Processing Advanced Thermoset Fiber Composites	p. 339
8.1 Introduction	p. 339
8.2 Autoclave Molding	p. 340
8.2.1 Part Preparation	p. 341
8.2.2 Material and Process Parameters	p. 341
8.2.3 Processing Steps	p. 348
8.2.4 Critical Issues	p. 348
8.2.5 Flow Model for Autoclave Processing	p. 349
8.3 Liquid Composite Molding	p. 356
8.3.1 Similarities and Differences Between Various LCM Processes	p. 356
8.3.2 Important Components of LCM Processes	p. 361
8.3.3 Modeling the Process Issues in LCM	p. 367
8.3.4 Process Models	p. 375
8.3.5 Resin Flow	p. 376
8.3.6 Heat Transfer and Cure	p. 382
8.3.7 Numerical Simulation of Resin Flow in LCM Processes	p. 390
8.4 Filament Winding of Thermosetting Matrix Composites	p. 393
8.4.1 Introduction	p. 393
8.4.2 Process Models	p. 395
8.5 Summary and Outlook	p. 402
8.6 Exercises	p. 403
8.6.1 Questions	p. 403
8.6.2 Fill in the Blanks	p. 405
8.6.3 Problems	p. 407
Bibliography	p. 409
Index	p. 433

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