Process Modeling in Composites Manufacturing,9780824708603

Process Modeling in Composites Manufacturing

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Edition: 1st
ISBN13: 9780824708603
ISBN10: 0824708601
Format: Hardcover
Pub. Date: 2002-08-28
Publisher(s): CRC Press
List Price: $235.33

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Summary

An ideal introductory text, this book helps readers understand and improve current manufacturing processes as well as invent novel composite processing techniques. It includes qualitative questions and fill-in-the-blank exercises along with quantitative problems. The contents covers transport equations especially geared towards polymer flows, the basics of fluid mechanics and heat transfer principles, short fiber suspension and advanced thermoplastic manufacturing methods, reaction and crystallization kinetics and permeability of fabrics, conventional assumptions in polymer composite processing, and modeling tools such as dimensionless analysis and closed forms solutions.

Author Biography

Suresh G. Advani is Associate Director, Center for Composite Materials, and Professor of Mechanical Engineering, University of Delaware, Newark E. Murat Sozer is Assistant Professor of Mechanical Engineering, Koc University, Istanbul, Turkey

Table of Contents

Preface iii
Introduction
1(22)
Motivation and Contents
1(1)
Preliminaries
2(2)
Polymer Matrices for Composites
4(7)
Polymer Resins
7(2)
Comparison Between Thermoplastic and Thermoset Polymers
9(2)
Additives and Inert Fillers
11(1)
Fibers
11(2)
Fiber-Matrix Interface
12(1)
Classification
13(3)
Short Fiber Composites
13(2)
Advanced Composites
15(1)
General Approach to Modeling
16(2)
Organization of the Book
18(1)
Exercises
18(5)
Questions
18(1)
Fill in the Blanks
19(4)
Overview of Manufacturing Processes
23(40)
Background
23(1)
Classification Based on Dominant Flow Process
24(1)
Short Fiber Suspension Manufacturing Methods
25(12)
Injection Molding
25(7)
Extrusion
32(2)
Compression Molding
34(3)
Advanced Thermoplastic Manufacturing Methods
37(9)
Sheet Forming
38(3)
Thermoplastic Pultrusion
41(3)
Thermoplastic Tape Lay-Up Process
44(2)
Advanced Thermoset Composite Manufacturing Methods
46(8)
Autoclave Processing
46(3)
Liquid Composite Molding
49(3)
Filament Winding
52(2)
Exercises
54(9)
Questions
54(4)
Fill in the Blanks
58(5)
Transport Equations for Composite Processing
63(48)
Introduction to Process Models
63(1)
Conservation of Mass (Continuity Equation)
64(6)
Conservation of Mass
65(4)
Mass Conservation for Resin with Presence of Fiber
69(1)
Conservation of Momentum (Equation of Motion)
70(5)
Stress-Strain Rate Relationship
75(9)
Kinematics of Fluid
75(5)
Newtonian Fluids
80(4)
Examples on Use of Conservation Equations to Solve Viscous Flow Problems
84(11)
Boundary Conditions
84(3)
Solution Procedure
87(8)
Conservation of Energy
95(12)
Heat Flux-Temperature Gradient Relationship
101(2)
Thermal Boundary Conditions
103(4)
Exercises
107(4)
Questions
107(1)
Problems
108(3)
Constitutive Laws and Their Characterization
111(62)
Introduction
111(1)
Resin Viscosity
112(9)
Shear Rate Dependence
114(4)
Temperature and Cure Dependence
118(3)
Viscosity of Aligned Fiber Thermoplastic Laminates
121(8)
Suspension Viscosity
129(8)
Regimes of Fiber Suspension
129(7)
Constitutive Equations
136(1)
Reaction Kinetics
137(9)
Techniques to Monitor Cure: Macroscopic Characterization
141(2)
Technique to Monitor Cure: Microscopic Characterization
143(1)
Effect of Reinforcements on Cure Kinetics
144(2)
Crystallization Kinetics
146(5)
Introduction
146(1)
Solidification and Crystallization
146(1)
Background
147(1)
Crystalline Structure
148(1)
Spherulitic Growth
149(1)
Macroscopic Crystallization
150(1)
Permeability
151(10)
Permeability and Preform Parameters
155(1)
Analytic and Numerical Characterization of Permeability
156(1)
Experimental Characterization of Permeability
157(4)
Fiber Stress
161(3)
Exercises
164(9)
Questions
164(3)
Fill in the Blanks
167(2)
Problems
169(4)
Model Simplifications and Solution
173(54)
Introduction
173(2)
Usefulness of Models
174(1)
Formulation of Models
175(5)
Problem Definition
175(2)
Building the Mathematical Model
177(1)
Solution of the Equations
177(1)
Model Assessment
178(1)
Revisions of the Model
179(1)
Model and Geometry Simplifications
180(3)
Dimensionless Analysis and Dimensionless Numbers
183(15)
Dimensionless Numbers Used in Composites Processing
190(8)
Customary Assumptions in Polymer Composite Processing
198(3)
Quasi-Steady State
198(1)
Fully Developed Region and Entrance Effects
199(1)
Lubrication Approximation
200(1)
Thin Shell Approximation
201(1)
Boundary Conditions for Flow Analysis
201(4)
In Contact with the Solid Surface
201(1)
In Contact with Other Fluid Surfaces
202(1)
Free Surfaces
202(1)
No Flow out of the Solid Surface
202(1)
Specified Conditions
203(1)
Periodic Boundary Condition
203(1)
Temperature Boundary Conditions
203(2)
Convection of Variables
205(1)
Process Models from Simplified Geometries
206(5)
Model Construction Based on Simple Geometries
209(2)
Mathematical Tools for Simplification
211(5)
Tansformation of Coordinates
211(2)
Superposition
213(2)
Decoupling of Equations
215(1)
Solution Methods
216(3)
Closed Form Solutions
217(2)
Numerical Methods
219(2)
Validation
221(2)
Various Approaches for Validation
221(2)
Exercises
223(4)
Questions
223(2)
Problems
225(2)
Short Fiber Composites
227(64)
Introduction
227(2)
Compression Molding
229(26)
Basic Processing Steps [1]
229(1)
Applications [1]
230(1)
Flow Modeling
231(1)
Thin Cavity Models
231(3)
Hele-Shaw Model
234(4)
Lubricated Squeeze Flow Model
238(5)
Hele-Shaw Model with a Partial Slip Boundary Condition [2]
243(5)
Heat Transfer and Cure
248(3)
Cure
251(1)
Coupling of Heat Transfer with Cure
252(2)
Fiber Orientation
254(1)
Extrusion
255(10)
Flow Modeling
257(3)
Calculation of Power Requirements [3]
260(2)
Variable Channel Length [3]
262(1)
Newtonian Adiabatic Analysis [3]
263(2)
Injection Molding
265(20)
Process Description
265(2)
Materials
267(1)
Applications
267(1)
Critical Issues
268(1)
Model Formulation for Injection Molding
269(11)
Fiber Orientation
280(5)
Exercises
285(6)
Questions
285(2)
Fill in the Blanks
287(2)
Problems
289(2)
Advanced Thermoplastic Composite Manufacturing Processes
291(48)
Introduction
291(1)
Composite Sheet Forming Processes
292(7)
Diaphragm Forming
293(1)
Matched Die Forming
293(2)
Stretch and Roll Forming
295(1)
Deformation Mechanisms
296(3)
Pultrusion
299(9)
Thermoset Versus Thermoplastics Pultrusion
300(1)
Cell Model [4]
300(8)
Thermal Model
308(3)
Transient Heat Transfer Equation
308(2)
Viscous Dissipation
310(1)
On-line Consolidation of Thermoplastics
311(22)
Introduction to Consolidation Model
314(1)
Importance of Process Modeling
314(2)
Consolidation Process Model
316(1)
Model Assumptions and Simplifications
316(1)
Governing Equations
317(5)
Boundary Conditions
322(1)
Rheology of the Composite
323(1)
Model Solutions
324(7)
Inverse Problem of Force Control
331(1)
Extended Consolidation Model
331(2)
Exercises
333(6)
Questions
333(1)
Fill in the Blanks
334(3)
Problems
337(2)
Processing Advanced Thermoset Fiber Composites
339(70)
Introduction
339(1)
Autoclave Molding
340(16)
Part Preparation
341(1)
Material and Process Parameters
341(7)
Processing Steps
348(1)
Critical Issues
348(1)
Flow Model for Autoclave Processing
349(7)
Liquid Composite Molding
356(37)
Similarities and Differences Between Various LCM Processes
356(5)
Important Components of LCM Processes
361(6)
Modeling the Process Issues in LCM
367(8)
Process Models
375(1)
Resin Flow
376(6)
Heat Transfer and Cure
382(8)
Numerical Simulation of Resin Flow in LCM Processes
390(3)
Filament Winding of Thermosetting Matrix Composites
393(9)
Introduction
393(2)
Process Models
395(7)
Summary and Outlook
402(1)
Exercises
403(6)
Questions
403(2)
Fill in the Blanks
405(2)
Problems
407(2)
Bibliography 409(24)
Index 433

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