Process Modeling in Composites Manufacturing (Manufacturing Engineering and Materials Processing, 59)

Process Modeling In Composites Manufacturing......Page 1 Dedication......Page 5 Preface......Page 6 Contents......Page 7 Contents......Page 0 1.1 Motivation And Contents......Page 12 1.2 Preliminaries......Page 13 1.3 Polymer Matrices For Composites......Page 15 1.3.1 Polymer Resins......Page 18 1.3.2 Comparison Between Thermoplastic And Thermoset Polymers......Page 20 1.4 Fibers......Page 22 1.4.1 Fiber- Matrix Interface......Page 23 1.5.1 Short Fiber Composites......Page 24 1.5.2 Advanced Composites......Page 26 1.6 General Approach To Modeling......Page 27 1.8.1 Questions......Page 29 1.8.2 Fill In The Blanks......Page 30 2.1 Background......Page 33 2.2 Classification Based On Dominant Flow Process......Page 34 Process......Page 35 Precursor Materials......Page 38 Transport Issues......Page 39 Applications......Page 41 Process......Page 42 Transport Issues......Page 43 2.3.3 Compression Molding......Page 44 Precursor Material Forms......Page 45 Process......Page 46 2.4 Advanced Thermoplastic Manufacturing Methods......Page 47 Process And Precursor Materials......Page 48 Sheet Forming Methods......Page 49 Transport And Other Issues......Page 50 Process......Page 51 Transport Issues......Page 52 Process......Page 54 Transport Issues......Page 55 2.5.1 Autoclave Processing......Page 56 Process......Page 57 Transport Issues......Page 58 Process......Page 59 Process......Page 62 2.6.1 Questions......Page 64 2.6.2 Fill In The Blanks......Page 68 3.1 Introduction To Process Models......Page 73 3.2 Conservation Of Mass (continuity Equation)......Page 74 3.2.1 Conservation Of Mass......Page 75 3.2.2 Mass Conservation For Resin With Presence Of Fiber......Page 79 3.3 Conservation Of Momentum (equation Of Motion)......Page 80 3.4.1 Kinematics Of Fluid......Page 85 3.4.2 Newtonian Fluids......Page 90 3.5.1 Boundary Conditions......Page 94 3.5.2 Solution Procedure......Page 97 3.6 Conservation Of Energy......Page 105 3.6.1 Heat Flux-temperature Gradient Relationship......Page 111 3.6.2 Thermal Boundary Conditions......Page 113 3.7.1 Questions......Page 117 3.7.2 Problems......Page 118 4.1 Introduction......Page 120 4.2 Resin Viscosity......Page 121 4.2.1 Shear Rate Dependence......Page 123 4.2.2 Temperature And Cure Dependence......Page 127 4.3 Viscosity Of Aligned Fiber Thermoplastic Laminates......Page 130 4.4.1 Regimes Of Fiber Suspension......Page 138 4.4.2 Constitutive Equations......Page 145 4.5 Reaction Kinetics......Page 146 4.5.1 Techniques To Monitor Cure: Macroscopic Characterization......Page 150 4.5.2 Technique To Monitor Cure: Microscopic Characterization......Page 152 4.5.3 Effect Of Reinforcements On Cure Kinetics......Page 153 4.6.2 Solidification And Crystallization......Page 155 4.6.3 Background......Page 156 4.6.4 Crystalline Structure......Page 157 4.6.5 Spherulitic Growth......Page 158 4.6.6 Macroscopic Crystallization......Page 159 4.7 Permeability......Page 160 4.7.1 Permeability And Preform Parameters......Page 164 4.7.2 Analytic And Numerical Characterization Of Permeability......Page 165 4.7.3 Experimental Characterization Of Permeability......Page 166 4.8 Fiber Stress......Page 170 4.9.1 Questions......Page 173 4.9.2 Fill In The Blanks......Page 176 4.9.3 Problems......Page 178 5.1 Introduction......Page 181 5.1.1 Usefulness Of Models......Page 182 5.2.1 Problem Definition......Page 183 5.2.3 Solution Of The Equations......Page 185 5.2.4 Model Assessment......Page 186 5.2.5 Revisions Of The Model......Page 187 5.3 Model And Geometry Simplifications......Page 188 5.4 Dimensionless Analysis And Dimensionless Numbers......Page 191 5.4.1 Dimensionless Numbers Used In Composites Processing......Page 198 5.5.1 Quasi-steady State......Page 206 5.5.2 Fully Developed Region And Entrance Effects......Page 207 5.5.3 Lubrication Approximation......Page 208 5.6.1 In Contact With The Solid Surface......Page 209 5.6.4 Flow Out Of The Solid Surface......Page 210 5.6.7 Temperature Boundary Conditions......Page 211 5.7 Convection Of Variables......Page 213 5.8 Process Models From Simplified Geometries......Page 214 5.8.1 Model Construction Based On Simple Geometries......Page 217 5.9.1 Transformation Of Coordinates......Page 219 5.9.2 Superposition......Page 221 5.9.3 Decoupling Of Equations......Page 223 5.10 Solution Methods......Page 224 5.10.1 Closed Form Solutions......Page 225 5.11 Numerical Methods......Page 227 5.12.1 Various Approaches For Validation......Page 229 5.13.1 Questions......Page 231 5.13.2 Problems......Page 233 6.1 Introduction......Page 235 6.2.1 Basic Processing Steps [i]......Page 237 6.2.2 Applications [1]......Page 238 6.2.4 Thin Cavity Models......Page 239 6.2.5 Hele-shaw Model......Page 242 6.2.6 Lubricated Squeeze Flow Model......Page 246 6.2.7 Hele-shaw Model With A Partial Slip Boundary Condition [2]......Page 251 6.2.8 Heat Transfer And Cure......Page 256 6.2.9 Cure......Page 259 6.2.10 Coupling Of Heat Transfer With Cure......Page 260 6.2.11 Fiber Orientation......Page 262 6.3 Extrusion......Page 263 6.3.1 Flow Modeling......Page 265 6.3.2 Calculation Of Power Requirements [3]......Page 268 6.3.3 Variable Channel Length [3]......Page 270 6.3.4 Newtonian Adiabatic Analysis [3]......Page 271 6.4.1 Process Description......Page 273 6.4.3 Applications......Page 275 6.4.4 Critical Issues......Page 276 6.4.5 Model Formulation For Injection Molding......Page 277 6.4.6 Fiber Orientation......Page 288 6.5.1 Questions......Page 293 6.5.2 Fill In The Blanks......Page 295 6.5.3 Problems......Page 297 7.1 Introduction......Page 299 7.2 Composite Sheet Forming Processes......Page 300 7.2.2 Matched Die Forming......Page 301 7.2.3 Stretch And Roll Forming......Page 303 7.2.4 Deformation Mechanisms......Page 304 7.3 Pultrusion......Page 307 7.3.2 Cell Model [4]......Page 308 7.4.1 Transient Heat Transfer Equation......Page 316 7.4.2 Viscous Dissipation......Page 318 7.5 On-line Consolidation Of Thermoplastics......Page 319 7.5.2 Importance Of Process Modeling......Page 322 7.5.4 Model Assumptions And Simplifications......Page 324 7.5.5 Governing Equations......Page 325 7.5.6 Boundary Conditions......Page 330 7.5.7 Rheology Of The Composite......Page 331 7.5.8 Model Solutions......Page 332 7.5.10 Extended Consolidation Model......Page 339 7.6.1 Questions......Page 341 7.6.2 Fill In The Blanks......Page 342 7.6.3 Problems......Page 345 8.1 Introduction......Page 346 8.2 Autoclave Molding......Page 347 8.2.2 Material And Process Parameters......Page 348 8.2.4 Critical Issues......Page 355 8.2.5 Flow Model For Autoclave Processing......Page 356 8.3.1 Similarities And Differences Between Various Lcm Processes......Page 363 8.3.2 Important Components Of Lcm Processes......Page 368 8.3.3 Modeling The Process Issues In Lcm......Page 374 8.3.4 Process Models......Page 382 8.3.5 Resin Flow......Page 383 8.3.6 Heat Transfer And Cure......Page 389 8.3.7 Numerical Simulation Of Resin Flow In Lcm Processes......Page 397 8.4.1 Introduction......Page 400 8.4.2 Process Models......Page 402 8.5 Summary And Outlook......Page 409 8.6.1 Questions......Page 410 8.6.2 Fill In The Blanks......Page 412 8.6.3 Problems......Page 414 Bibliography......Page 416 Ideal introductory text for seniors and first year graduate students in material science, industrial, mechanical, and chemical engineering tracks! Includes qualitative questions and fill-in-the-blank exercises along with quantitative problems!Helps the reader to understand and improve current manufacturing processes, as well as invent novel composite processing techniques!Process Modeling in Composites Manufacturing examinestransport equations especially geared towards polymer flowsthe basics of fluid mechanics and heat transfer principlesshort fiber suspension and advanced thermoplastic manufacturing methodsreaction and crystallization kinetics and permeability of fabricsconventional assumptions in polymer composite processingmodeling tools such as dimensionless analysis and closed forms solutionsProcess Modeling in Composites Manufacturing is essential reading for manufacturing, mechanical, industrial, material science, and chemical engineers, and will prove to be an invaluable text for upper-level undergraduate and graduate students in these disciplines. 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 m This text reinforces a qualitative understanding of transport phenomena and key issues in composites manufacturing to obtain results based on scientific principles rather then trial-and-error approaches