Numerical analysis of the thermomechanical behaviour of an integrally water-heated tool for composite manufacturing

Abstract

Integrally water-heated tooling is one of the technologies available for ‘out-of-autoclave’ processing of advanced thermoset polymer composites. Temperature variation and temperature cycling, during heating and cooling, affect the properties of tool material and may produce undesirable thermal effects that degrade the tool durability and performance, especially when the tool construction involves various materials. Hence, in the current study, the performance and the thermomechanical behaviour of an integrally water-heated tool have been investigated using finite element analysis method. The intended tool, in the current study, consists different materials of composite and metals and is designed to heat up to 90℃. Linear mechanical properties, coefficient of thermal expansions and transient heating curve of each tool part are determined experimentally and set during the numerical analysis of tool structure to calculate the static thermal load effects of deformation, stress and strain. Comparing the numerical thermal effects with the ultimate stresses and strains of the tool, materials concluded that no failure occurs with regard to static thermal loads. However, the calculated stresses are as much as the lowest magnitude of safety relates to the tool mould part made of Alepoxy.

Keywords

Composite integrally water-heated tool finite element analysis deformation

Get full access to this article

View all access options for this article.

References

Askeland

. The Science and engineering of materials, 6th ed. Stamford, CT: Cengage Learning, 2011.

Rogin

. The basics of pipe thermal expansion. Pumps Syst April 2010, pp. 42–55–42–55.

Herakovich

Hyer

. Damage-induced property changes in composites subjected to cyclic thermal loading. Eng Fract Mech 1986; 25: 779–791.

Carden

. Thermal fatigue – an analysis of the experimental method, USA: Oak Ridge National Laboratory, Atomic Energy Commision, 1963.

Chen

Nelson

. Thermal stress in bonded joints. J Res Develo 1979; 23: 179–188.

Bruno

Weiner

. Theory of Thermal stresses, USA: Dover Publications Inc., 2011, pp. 608–608.

Timoshenko

. Analysis of bi-metal thermostats. J Opt Soc Am 1925; 11: 233–255.

Fo-van

. Thermal contact stresses of bi-metal strip thermostat. Appl Math Mech 1983; 4: 363–376.

Suhir

. Interfacial stresses in bimetal thermostats. J Appl Mech 1989; 56: 595–600.

10.

Eischen

Chung

Kim

. Realistic modeling of edge effect stresses in bimaterial elements. J Electron Pack 1990; 112: 16–23.

11.

Timoshenko

Goodier

. Theory of elasticity, 2nd ed. USA: McGraw-Hill, 1951.

12.

Timoshenko

. Strength of materials, 3rd ed. New Jersey: D.Van Nostrand Company, Inc., 1956.

13.

Irfan

Chapman

. Thermal stresses in radiant tubes due to axial, circumferential and radial temperature distributions. Appl Therm Eng 2009; 29: 1913–1920.

14.

Crompton

. Thermal methods of polymer analysis, UK: Rapra Technology Ltd, 2013.

15.

Jones

. The principles of thermal sciences and their application to engineering, UK: Whittles Publishing, 2000.

16.

Hancox

. Thermal effects on polymer matrix composites: part 1. Thermal cycling. Mater Des 1998; 19: 85–91.

17.

Kamiya

. Bimodulus thermoelasticity considering temperature-dependent material properties. Mech Bimodul Mater 1979; 33: 29–37.

18.

Progoulakis

. Heated tooling for aerospace composites manufacture. Faculty of science and technology, UK: University of Plymouth, 2004, pp. 301–301.

19.

Shahidi E. Composite tooling solutions for new manufacturing. In: Proceedings of the 1st stade composite colloquium techniques, Stade, Germany, 7–8 September 2000.

20.

Cohen D, Hyer MW and Tompkins SS. The effects of thermal cycling on matrix cracking and stiffness changes in composite tubes. In: 16th SAMPE technical conference, 9–11 October 1984, pp.577–588. Albuquerque, New Mexico, USA.

21.

Tompkins

Williams

. Effects of thermal cycling on mechanical properties of graphite polyimide. J Spacecraft Rockets 1984; 21: 274–280.

22.

Abdalrahman

. Numerical simulation and experimental verification of heating performance of an integrally water-heated tool. Journal of reinforced plastics and composites, Autodesk, USA, 2016.

23.

Autodesk . Simulation composite design user’s guide, Autodesk, USA: Author, 2013.

24.

AST D790-07. Standard test methods for flextural properties of unreinforced and reinforced plastics and electrical insulating materials, 2007, 8.01.

25.

Petrescu

Mohora

Ispas

. The Determination of young modulus for cfrp using three point bending test at different span lengths. J Sci Bull Ser D 2013; 75: 121–128.

26.

ISO 14125. Fibre-reinforced plastic composites-determination of flexural properties, Brussels, Belgium: European Committee for Standardization, 1988.

27.

ASTM D5335-14. Standard test method for linear coefficient of thermal expansion of rock using bonded electric resistance strain gauges, West Conshohocken, PA: ASTM International Book of Standards, 2014.

28.

IPC. IPC-TM-650 test methods manual, USA: Association Connecting Electronics Industries, 2000.

29.

Scalea

FLD

. Measurement of thermal expansion coefficients of composites using strain gages. Exp Mech 1998; 38: 233–241.

30.

Davis

. Copper and copper alloys 2001. USA: Materials Park, OH : ASM International, 2001.