2nd Edition

Process Modeling in Composites Manufacturing

    630 Pages 348 B/W Illustrations
    by CRC Press

    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 Edition provides 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.


    Motivation and Contents


    Polymer Matrices for Composites



    General Approach to Modeling

    Organization of the Book

    Overview of Manufacturing Processes


    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


    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


    Short Fiber Composites

    Compression Molding


    Injection Molding


    Advanced Thermoplastic Manufacturing Processes

    Composite Sheet Forming Processes


    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




    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.