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Thermoplastic Processing vs. Traditional Composite Manufacturing Techniques: A Comparison, Study notes of Mechanical Engineering

Georgia Institute of Technology - Main CampusMechanical Engineering

An in-depth comparison between thermoplastic processing techniques, such as roll forming, matched die forming, hydroforming, vacuum forming in autoclave, and stretch forming, and traditional composite manufacturing techniques, including prepreg, manual lay-up, spray-up, vacuum bag, autoclave, matched die, rtm, pultrusion, and filament winding. The focus is on understanding the differences in processing, advantages, disadvantages, and applications of each method.

Typology: Study notes

Pre 2010

Uploaded on 08/05/2009

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koofers-user-nvl 🇺🇸

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ENG 4793: C omposite Mater ials and Pro cesses 1
Thermoplastic Processing
Techniques
ver 1
ENG 4793: C omposite Mater ials and Pro cesses 2
What is different?
+ No reactions (hopefully)
Saves time, easy storage
- High viscosity
Not tacky, stiff, higher t, T, and P
+ Fracture toughness
- Low interfacial bonding
+ Remelting
Correct defects, thermoforming
- Costs
Currently higher, ultimately lower
ENG 4793: C omposite Mater ials and Pro cesses 3
Roll Forming
ENG 4793: C omposite Mater ials and Pro cesses 4
Roll-formed Part
ENG 4793: C omposite Mater ials and Pro cesses 5ENG 4793: C omposite Mater ials and Pro cesses 6
Matched Die Forming
sample and
holder alignment pins
adjustment bolts
weights
pf3
pf4
pf5

Partial preview of the text

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ENG 4793: Composite Materials and Processes (^1)

Thermoplastic Processing

Techniques

ver 1

ENG 4793: Composite Materials and Processes (^2)

What is different?

  • No reactions (hopefully)

Saves time, easy storage

  • High viscosity

Not tacky, stiff, higher t, T, and P

  • Fracture toughness
  • Low interfacial bonding
  • Remelting

Correct defects, thermoforming

  • Costs

Currently higher, ultimately lower

ENG 4793: Composite Materials and Processes 3

Roll Forming

ENG 4793: Composite Materials and Processes 4

Roll-formed Part

ENG 4793: Composite Materials and Processes 5 ENG 4793: Composite Materials and Processes (^6)

Matched Die Forming

sample and

holder

alignment pins

adjustment bolts

weights

ENG 4793: Composite Materials and Processes (^7)

Matched Die Formed Part Defects

ENG 4793: Composite Materials and Processes (^8)

Press Forming of LDF

(long discontinuous fibers)

Formed component

after trimming

Clamp and

Heat material Transfer intoheated dies thermoform

ENG 4793: Composite Materials and Processes 9

Compression Molding

ENG 4793: Composite Materials and Processes 10

Compression Molding Sequence

ENG 4793: Composite Materials and Processes (^11)

Hood Cost vs. Production Volume

ENG 4793: Composite Materials and Processes (^12)

Hydroforming

ENG 4793: Composite Materials and Processes (^19)

Stretch Forming Sequence

ENG 4793: Composite Materials and Processes (^20)

Fiber Position

in Stretch

Formed Part

ENG 4793: Composite Materials and Processes 21

Tape Laying

ENG 4793: Composite Materials and Processes 22 ENG 4793: Composite Materials and Processes (^23)

Thermoplastics Processing Comparison

ENG 4793: Composite Materials and Processes (^24)

Thermoplastics vs. Thermosets

Processing Comparison

Process Comments
Prepreg Harder (melt, commingle, powder)
Manual Lay-up Need heat and pressure
Spray-up not done
Vacuum bag Less material, higher temperature (T)
Autoclave More T and P, less time (t)
Matched Die More T and P, less time (t)
RTM not commercial
Pultrusion More T and P, should be faster
Filament Winding More T and P, currently slower
  • ENG 4793: Composite Materials and Processes