Process modeling in composites manufacturing / Suresh G. Advani, E. Murat Sozer.

Includes bibliographical references and index.

Contents Preface About the Authors 1.Introduction 1.1.Motivation and Contents 1.2.Preliminaries 1.3.Polymer Matrices for Composites 1.3.1.Polymer Resins 1.3.2.Comparison between Thermoplastic and Thermoset Polymers 1.3.3.Additives and Inert Fillers 1.4.Fibers 1.4.1.Fiber-Matrix Interface 1.5.Classification 1.5.1.Short Fiber Composites 1.5.2.Advanced Composites 1.6.General Approach to Modeling 1.7.Organization of the Book 1.8.Exercises 1.8.1.Questions 1.8.2.Fill in the Blanks 2.Overview of Manufacturing Processes 2.1.Background 2.2.Classification Based on Dominant Flow Process 2.3.Short Fiber Suspension Manufacturing Methods 2.3.1.Injection Molding 2.3.2.Extrusion 2.3.3.Compression Molding 2.3.4.Structural Foam Molding 2.3.5.Rotational Molding 2.4.Advanced Thermoplastic Manufacturing Methods 2.4.1.Sheet Forming 2.4.2.Thermoplastic Pultrusion 2.4.3.Thermoplastic Tape Lay-Up Process 2.5.Advanced Thermoset Composite Manufacturing Methods 2.5.1.Autoclave Processing 2.5.2.Liquid Composite Molding 2.5.3.Filament Winding 2.6.Exercises 2.6.1.Questions 2.6.2.Fill in the Blanks 3.Transport Equations for Composite Processing 3.1.Introduction to Process Models 3.2.Conservation of Mass (Continuity Equation) 3.2.1.Conservation of Mass 3.2.2.Mass Conservation for Resin with Presence of Fibers 3.3.Conservation of Momentum (Equation of Motion) 3.4.Stress-Strain Rate Relationship 3.4.1.Kinematics of Fluid 3.4.2.Newtonian Fluids 3.5.Examples to Solve Viscous Flow Problems 3.5.1.Boundary Conditions 3.5.2.Solution Procedure 3.6.Conservation of Energy 3.6.1.Heat Flux-Temperature Gradient Relationship 3.6.2.Thermal Boundary Conditions 3.7.Exercises 3.7.1.Questions 3.7.2.Problems 4.Constitutive Laws and Their Characterization 4.1.Introduction 4.2.Resin Viscosity 4.2.1.Shear Rate Dependence 4.2.2.Temperature and Cure Dependence 4.3.Viscosity of Aligned Fiber Thermoplastic Laminates 4.4.Suspension Viscosity 4.4.1.Regimes of Fiber Suspension 4.4.2.Constitutive Equations 4.5.Reaction Kinetics 4.5.1.Techniques to Monitor Cure: Macroscopic Characterization 4.5.2.Technique to Monitor Cure: Microscopic Characterization 4.5.3.Effect of Reinforcements on Cure Kinetics 4.6.Thermoplastic Reactive Processing 4.7.Crystallization Kinetics 4.7.1.Introduction 4.7.2.Solidification and Crystallization 4.7.3.Background 4.7.4.Crystalline Structure 4.7.5.Spherulitic Growth 4.7.6.Macroscopic Crystallization 4.8.Permeability 4.8.1.Permeability and Preform Parameters 4.8.2.Analytic and Numerical Characterization of Permeability 4.8.3.Experimental Characterization of Permeability 4.9.Fiber Stress 4.10.Exercises 4.10.1.Questions 4.10.2.Fill in the Blanks 4.10.3.Problems 5.Model Simplifications and Solutions 5.1.Introduction 5.1.1.Usefulness of Models 5.2.Formulation of Models 5.2.1.Problem Definition 5.2.2.Building the Mathematical Model 5.2.3.Solution of the Equations 5.2.4.Model Assessment 5.2.5.Revisions of the Model 5.3.Model and Geometry Simplifications 5.4.Dimensionless Analysis and Dimensionless Numbers 5.4.1.Dimensionless Numbers Used in Composites Processing 5.5.Customary Assumptions in Polymer Composite Processing 5.5.1.Quasi-Steady State 5.5.2.Fully Developed Region and Entrance Effects 5.5.3.Lubrication Approximation 5.5.4.Thin Shell Approximation 5.6.Boundary Conditions for Flow Analysis 5.6.1.In Contact with a Solid Surface 5.6.2.In Contact with Other Fluid Surfaces 5.6.3.Free Surfaces 5.6.4.No Flow out of a Solid Surface 5.6.5.Specified Conditions 5.6.6.Periodic Boundary Condition 5.6.7.Temperature Boundary Conditions 5.7.Convection of Variables 5.8.Process Models from Simplified Geometries 5.8.1.Model Construction Based on Simple Geometries 5.9.Mathematical Tools for Simplification 5.9.1.Transformation of Coordinates 5.9.2.Superposition 5.9.3.Decoupling of Equations 5.10.Solution Methods 5.10.1.Closed-Form Solutions 5.1.Numerical Methods 5.12.Validation 5.12.1.Various Approaches for Validation 5.13.Exercises 5.13.1.Questions 5.13.2.Problems 6.Short Fiber Composites 6.1.Introduction 6.2.Compression Molding 6.2.1.Basic Processing Steps [1] 6.2.2.Applications [1] 6.2.3.Flow Modeling 6.2.4.Thin Cavity Models 6.2.5.Hele-Shaw Model 6.2.6.Lubricated Squeeze Flow Model 6.2.7.Hele-Shaw Model with a Partial Slip Boundary Condition [2-4] 6.2.8.Heat Transfer and Cure 6.2.9.Cure 6.2.10.Coupling of Heat Transfer with Cure 6.2.11.Fiber Orientation 6.3.Extrusion 6.3.1.Flow Modeling 6.3.2.Calculation of Power Requirements [5] 6.3.3.Variable Channel Length [5] 6.3.4.Newtonian Adiabatic Analysis [5] 6.4.Injection Molding 6.4.1.Process Description 6.4.2.Materials 6.4.3.Applications 6.4.4.Critical Issues 6.4.5.Model Formulation for Injection Molding 6.4.6.Fiber Orientation 6.5.Exercises 6.5.1.Questions 6.5.2.Fill in the Blanks 6.5.3.Problems 7.Adv. Thermoplastic Composite Manuf. Processes 7.1.Introduction 7.2.Composite Sheet Forming Processes 7.2.1.Diaphragm Forming 7.2.2.Matched Die Forming 7.2.3.Stretch and Roll Forming 7.2.4.Deformation Mechanisms 7.3.Pultrusion 7.3.1.Thermoset versus Thermoplastic Pultrusion 7.3.2.Cell Model [6] 7.4.Thermal Model 7.4.1.Transient Heat Transfer Equation 7.4.2.Viscous Dissipation 7.5.On-Line Consolidation of Thermoplastics 7.5.1.Introduction to Consolidation Model 7.5.2.Importance of Process Modeling 7.5.3.Consolidation Process Model 7.5.4.Model Assumptions and Simplifications 7.5.5.Governing Equations 7.5.6.Boundary Conditions 7.5.7.Rheology of the Composite 7.5.8.Model Solutions 7.5.9.Inverse Problem of Force Control 7.5.10.Extended Consolidation Model 7.6.Exercises 7.6.1.Questions 7.6.2.Fill in the Blanks 7.6.3.Problems 8.Processing Advanced Thermoset Fiber Composites 8.1.Introduction 8.2.Autoclave Molding 8.2.1.Part Preparation 8.2.2.Material and Process Parameters 8.2.3.Processing Steps 8.2.4.Critical Issues 8.2.5.Flow Model for Autoclave Processing 8.3.Liquid Composite Molding 8.3.1.Similarities and Differences between Various LCM Processes 8.3.2.Important Components of LCM Processes 8.3.3.Modeling Flow Issues in LCM 8.3.4.Process Models 8.3.5.Resin Flow 8.3.6.Heat Transfer and Cure 8.3.7.Numerical Simulation of Resin Flow in LCM Processes 8.3.8.Case Studies 8.3.9.Numerical Solution of Pressure and Velocity Distributions at the End of Mold Filling Using Finite Difference Method 8.3.10.Liquid Injection Molding Simulation (LIMS) 8.3.11.Case Studies Using LIMS 8.4.Filament Winding of Thermosetting Matrix Composites 8.4.1.Introduction 8.4.2.Process Models 8.5.Summary and Outlook 8.6.Exercises 8.6.1.Questions 8.6.2.Fill in the Blanks 8.6.3.Problems A.MATLAB Files B.Solution to Example 8.13 Using FDM C.Additional Examples with LIMS to Model Liquid Mold Filling Bibliography Index