Process Modeling in Composites Manufacturing
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Book Description
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.
Table of Contents
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
Editor(s)
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.