TY  - BOOK
AU  - Advani,Suresh G.
AU  - Sozer,E.Murat
TI  - Process modeling in composites manufacturing
SN  - 9781420090826
AV  - TA418.9.C6 A325 2011
PY  - 2011///
CY  - Boca Raton, FL
PB  - CRC Press
KW  - Composite materials
KW  - Manufacturing processes
N1  - 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
ER  -