Process Modeling in Composites Manufacturing [Kietas viršelis]

Preface		iii
Introduction		1	(22)
Motivation and Contents		1	(1)
Preliminaries		2	(2)
Polymer Matrices for Composites		4	(7)
Polymer Resins		7	(2)
Comparison Between Thermoplastic and Thermoset Polymers		9	(2)
Additives and Inert Fillers		11	(1)
Fibers		11	(2)
Fiber-Matrix Interface		12	(1)
Classification		13	(3)
Short Fiber Composites		13	(2)
Advanced Composites		15	(1)
General Approach to Modeling		16	(2)
Organization of the Book		18	(1)
Exercises		18	(5)
Questions		18	(1)
Fill in the Blanks		19	(4)
Overview of Manufacturing Processes		23	(40)
Background		23	(1)
Classification Based on Dominant Flow Process		24	(1)
Short Fiber Suspension Manufacturing Methods		25	(12)
Injection Molding		25	(7)
Extrusion		32	(2)
Compression Molding		34	(3)
Advanced Thermoplastic Manufacturing Methods		37	(9)
Sheet Forming		38	(3)
Thermoplastic Pultrusion		41	(3)
Thermoplastic Tape Lay-Up Process		44	(2)
Advanced Thermoset Composite Manufacturing Methods		46	(8)
Autoclave Processing		46	(3)
Liquid Composite Molding		49	(3)
Filament Winding		52	(2)
Exercises		54	(9)
Questions		54	(4)
Fill in the Blanks		58	(5)
Transport Equations for Composite Processing		63	(48)
Introduction to Process Models		63	(1)
Conservation of Mass (Continuity Equation)		64	(6)
Conservation of Mass		65	(4)
Mass Conservation for Resin with Presence of Fiber		69	(1)
Conservation of Momentum (Equation of Motion)		70	(5)
Stress-Strain Rate Relationship		75	(9)
Kinematics of Fluid		75	(5)
Newtonian Fluids		80	(4)
Examples on Use of Conservation Equations to Solve Viscous Flow Problems		84	(11)
Boundary Conditions		84	(3)
Solution Procedure		87	(8)
Conservation of Energy		95	(12)
Heat Flux-Temperature Gradient Relationship		101	(2)
Thermal Boundary Conditions		103	(4)
Exercises		107	(4)
Questions		107	(1)
Problems		108	(3)
Constitutive Laws and Their Characterization		111	(62)
Introduction		111	(1)
Resin Viscosity		112	(9)
Shear Rate Dependence		114	(4)
Temperature and Cure Dependence		118	(3)
Viscosity of Aligned Fiber Thermoplastic Laminates		121	(8)
Suspension Viscosity		129	(8)
Regimes of Fiber Suspension		129	(7)
Constitutive Equations		136	(1)
Reaction Kinetics		137	(9)
Techniques to Monitor Cure: Macroscopic Characterization		141	(2)
Technique to Monitor Cure: Microscopic Characterization		143	(1)
Effect of Reinforcements on Cure Kinetics		144	(2)
Crystallization Kinetics		146	(5)
Introduction		146	(1)
Solidification and Crystallization		146	(1)
Background		147	(1)
Crystalline Structure		148	(1)
Spherulitic Growth		149	(1)
Macroscopic Crystallization		150	(1)
Permeability		151	(10)
Permeability and Preform Parameters		155	(1)
Analytic and Numerical Characterization of Permeability		156	(1)
Experimental Characterization of Permeability		157	(4)
Fiber Stress		161	(3)
Exercises		164	(9)
Questions		164	(3)
Fill in the Blanks		167	(2)
Problems		169	(4)
Model Simplifications and Solution		173	(54)
Introduction		173	(2)
Usefulness of Models		174	(1)
Formulation of Models		175	(5)
Problem Definition		175	(2)
Building the Mathematical Model		177	(1)
Solution of the Equations		177	(1)
Model Assessment		178	(1)
Revisions of the Model		179	(1)
Model and Geometry Simplifications		180	(3)
Dimensionless Analysis and Dimensionless Numbers		183	(15)
Dimensionless Numbers Used in Composites Processing		190	(8)
Customary Assumptions in Polymer Composite Processing		198	(3)
Quasi-Steady State		198	(1)
Fully Developed Region and Entrance Effects		199	(1)
Lubrication Approximation		200	(1)
Thin Shell Approximation		201	(1)
Boundary Conditions for Flow Analysis		201	(4)
In Contact with the Solid Surface		201	(1)
In Contact with Other Fluid Surfaces		202	(1)
Free Surfaces		202	(1)
No Flow out of the Solid Surface		202	(1)
Specified Conditions		203	(1)
Periodic Boundary Condition		203	(1)
Temperature Boundary Conditions		203	(2)
Convection of Variables		205	(1)
Process Models from Simplified Geometries		206	(5)
Model Construction Based on Simple Geometries		209	(2)
Mathematical Tools for Simplification		211	(5)
Tansformation of Coordinates		211	(2)
Superposition		213	(2)
Decoupling of Equations		215	(1)
Solution Methods		216	(3)
Closed Form Solutions		217	(2)
Numerical Methods		219	(2)
Validation		221	(2)
Various Approaches for Validation		221	(2)
Exercises		223	(4)
Questions		223	(2)
Problems		225	(2)
Short Fiber Composites		227	(64)
Introduction		227	(2)
Compression Molding		229	(26)
Basic Processing Steps [ 1]		229	(1)
Applications [ 1]		230	(1)
Flow Modeling		231	(1)
Thin Cavity Models		231	(3)
Hele-Shaw Model		234	(4)
Lubricated Squeeze Flow Model		238	(5)
Hele-Shaw Model with a Partial Slip Boundary Condition [ 2]		243	(5)
Heat Transfer and Cure		248	(3)
Cure		251	(1)
Coupling of Heat Transfer with Cure		252	(2)
Fiber Orientation		254	(1)
Extrusion		255	(10)
Flow Modeling		257	(3)
Calculation of Power Requirements [ 3]		260	(2)
Variable Channel Length [ 3]		262	(1)
Newtonian Adiabatic Analysis [ 3]		263	(2)
Injection Molding		265	(20)
Process Description		265	(2)
Materials		267	(1)
Applications		267	(1)
Critical Issues		268	(1)
Model Formulation for Injection Molding		269	(11)
Fiber Orientation		280	(5)
Exercises		285	(6)
Questions		285	(2)
Fill in the Blanks		287	(2)
Problems		289	(2)
Advanced Thermoplastic Composite Manufacturing Processes		291	(48)
Introduction		291	(1)
Composite Sheet Forming Processes		292	(7)
Diaphragm Forming		293	(1)
Matched Die Forming		293	(2)
Stretch and Roll Forming		295	(1)
Deformation Mechanisms		296	(3)
Pultrusion		299	(9)
Thermoset Versus Thermoplastics Pultrusion		300	(1)
Cell Model [ 4]		300	(8)
Thermal Model		308	(3)
Transient Heat Transfer Equation		308	(2)
Viscous Dissipation		310	(1)
On-line Consolidation of Thermoplastics		311	(22)
Introduction to Consolidation Model		314	(1)
Importance of Process Modeling		314	(2)
Consolidation Process Model		316	(1)
Model Assumptions and Simplifications		316	(1)
Governing Equations		317	(5)
Boundary Conditions		322	(1)
Rheology of the Composite		323	(1)
Model Solutions		324	(7)
Inverse Problem of Force Control		331	(1)
Extended Consolidation Model		331	(2)
Exercises		333	(6)
Questions		333	(1)
Fill in the Blanks		334	(3)
Problems		337	(2)
Processing Advanced Thermoset Fiber Composites		339	(70)
Introduction		339	(1)
Autoclave Molding		340	(16)
Part Preparation		341	(1)
Material and Process Parameters		341	(7)
Processing Steps		348	(1)
Critical Issues		348	(1)
Flow Model for Autoclave Processing		349	(7)
Liquid Composite Molding		356	(37)
Similarities and Differences Between Various LCM Processes		356	(5)
Important Components of LCM Processes		361	(6)
Modeling the Process Issues in LCM		367	(8)
Process Models		375	(1)
Resin Flow		376	(6)
Heat Transfer and Cure		382	(8)
Numerical Simulation of Resin Flow in LCM Processes		390	(3)
Filament Winding of Thermosetting Matrix Composites		393	(9)
Introduction		393	(2)
Process Models		395	(7)
Summary and Outlook		402	(1)
Exercises		403	(6)
Questions		403	(2)
Fill in the Blanks		405	(2)
Problems		407	(2)
Bibliography		409	(24)
Index		433

Murat Sozer is Associate Professor of the Mechanical Engineering Department, Koc University, Istanbul, Turkey. His research interests are in manufacturing of composite materials and fluid dynamics. He and his co-authors S. Bickerton and S. G. Advani received The Outstanding Technical Paper Award by the Composites Manufacturing Association (CMA) of the Society of Manufacturing Engineers (SME) in recognition of outstanding contribution to the composites manufacturing body of knowledge for the technical paper at the Composites Manufacturing and Tooling 2000 Conference, Newport Beach, California, February 23-25, 2000. Before joining Koc University in 2000, he worked as a post-doctoral researcher at the Center for Composite Materials, University of Delaware between 1997 and 2000, and as a technical editor for Prentice-Hall Publishers between 1996 and 1997.









Suresh G. Advani is the George W. Laird Professor of Mechanical Engineering and Associate Director of Center for Composite Materials at the University of Delaware. He received his Bachelor of Technology Degree in Mechanical Engineering from I.I.T. Bombay in 1982 and his Ph. D in Mechanical Engineering from University of Illinois at Urbana-Champaign in 1987. His research interests are in rheology; fluid mechanics and heat transfer as applied to composite processing and alternate energy sources such as fuel cells and hydrogen storage. Advani is a Fellow of American Society of Mechanical Engineers and is the North American Editor for the journal Composites A: Applied Science and Manufacturing. Professor Advani serves also on the Scientific Advisory Committee of Computer Methods in Engineering Science and International Conference on Flow Processes in Composites Manufacturing. He is a author or co-author of over 200 archival journal papers.