Process Modeling in Composites Manufacturing

Introduction

Motivation and Contents

Preliminaries

Polymer Matrices for Composites

Fibers

Classification

General Approach to Modeling

Organization of the Book

Overview of Manufacturing Processes

Background

Classification Based on Dominant Flow Process

Short Fiber Suspension Manufacturing Methods

Advanced Thermoplastic Manufacturing Methods

Advanced Thermoset Composite Manufacturing Methods

Transport Equations for Composite Processing

Introduction to Process Models

Conservation of Mass (Continuity Equation)

Conservation of Momentum (Equation of Motion)

Stress-Strain Rate Relationship

Examples to Solve Viscous Flow Problems

Conservation of Energy

Constitutive Laws and Their Characterization

Resin Viscosity

Viscosity of Aligned Fiber Thermoplastic Laminates

Suspension Viscosity

Reaction Kinetics

Thermoplastic Reactive Processing

Crystallization Kinetics

Permeability

Fiber Stress

Model Simplifications and Solution

Formulation of Models

Model and Geometry Simplifications

Dimensionless Analysis and Dimensionless Numbers

Customary Assumptions in Polymer Composite Processing

Boundary Conditions for Flow Analysis

Convection of Variables

Process Models from Simplified Geometries

Mathematical Tools for Simplification

Solution Methods

Numerical Methods

Validation

Short Fiber Composites

Compression Molding

Extrusion

Injection Molding

Exercises

Advanced Thermoplastic Manufacturing Processes

Composite Sheet Forming Processes

Pultrusion

Thermal Model

Online Consolidation of Thermoplastics

Processing Advanced Thermoset Fiber Composites

Autoclave Molding

Liquid Composite Molding

Filament Winding of Thermosetting Matrix Composites

Summary and Outlook

MATLAB Files

Solution to Example 8.13 using FDM

Additional Examples with LIMS to Model Liquid Mold Filling

Bibliography

Index

Biography

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.