The on-line consolidation of thermoplastic composites is a relatively new technology that can be used to manufacture composite parts with complex geometries. The localized melting/solidification technique employed in this process can reduce the residual stresses and allow for improved dimensional stability and performance. An additional advantage of this technique is the elimination of the curing steps which are necessary in the processing of thermoset-matrix composites. This article presents the effects of process ing parameters on processability in on-line consolidation of thermoplastic composites for tape-laying and filament-winding processes employing anisotropic thermal analyses. The results show that the heater size, preheating conditions, and tow thickness can signifi cantly affect the processing window which, in turn, affects the production rate and the quality of the parts.
References
1.
Ghasemi Nejhad, M.N.1992 "Three-Dimensional Thermal and Residual Stress Analysis of In-Situ Thermoplastic Composite Filament Winding," Ph D thesis. Department of Mechanical Engineering, Umversity of Delaware, Newark, Delaware
2.
Ghasemi Nejhad, M.N. , J.W. Galespie, Jr and R.D. Cope1992 "Prediction of Process-Induced Stresses for In-Situ Thermoplastic Filament Winding of Cylinders," Proc. 3rd Int Conf CADCOMP 92 Computer Arclecl Design in Composite Material Technology , Newark, Delaware, 3 225-253
3.
Chang, I.Y. and J.K. Lees1988"Recent Development in Thermoplastic Composites. A Review of Matrix Systems and Processing Methods," Journal of Thermoplastic Composite Materials,1277-295
4.
Wang, E. and T. Gutowski1990 "Cost Comparison between Thermoplastic and Thermoset Composites " SAMPE Journal, 26(6) 19-26
5.
Gnffiths, G.R. , W.D. Hillier and J A S Whiting1988 " Thermoplastic Composite Manufacturing Technology for a Flight Standard Tailplane " In Proceedings, 33rd International SAMPE Symposium, Anaheim, CA, 33308-316
6.
Beyeler, E.P. , W. Phillips and S.I. Guçen1988 " Experimental Investigation of Laser-Assisted Thermoplastic Tape Consolidation ," Journal of Thermoplastic Composite Materials , I107-121
7.
Gilmore, S.D.1991Thermal and Resrdual Stress Analysrs in Processing of Thermoplastic Composites, Ph D thesis, Department of Mechanical Engineering, University of Delaware, Newark, DE
8.
Egerton, M.W. and M.B. Gruber1988"Thermoplastic Filament Winding Demonstrating Economics and Properties via In-Situ Consolidation," In Proceedings, 33rd International SAMPE Symposium, Anaheim, CA, 3335-46
9.
Egerton, M.W. and M.B. Gruber1989 "Thermoplastic Filament Wound Parts Demonstrating Properties in Crush Tube and Torque Tube Applications," In Proceedings, 34th International SAMPE Svmposium, Reno, NV, 34159-170
10.
Winkel, J.D. and J.R. Hurdle1988 "Mechanical Performance of Filament Wound Polyphenylene Sulfide Thermoplastic Composite Tubular Structures " In Proceedings, 33rd International SAMPE Svmposiuin, Anaheim, CA, 33816-828.
11.
Hollingsworth, R.D. and D.R. Osment1987 "Filament Wound Thermoplastic Matrix Pressure Vessels," In Proceedings, 32nd International SAMPE Symposium, Anaheim, CA, 32662-669
12.
Werderman, C. , K. Friedrich, M. Cirino and R.B. Pipes1989"Design and Fabrication of an On-Line Consolidation Facility for Thermoplastic Composites," Journal of Thermoplastic Composite Materials , 2293-306
13.
Hummler, J. , S.K. Lee and K.V. Stemer1991 "Recent Advances In Thermoplastic Robotic Filament Winding," Technical Report CCM-91-06, Center for Composite Materials ReportUmversity of Delaware,Newark, DE
14.
Calms, E.P. and G.S. Spnnger1988 "Filament Winding Process Simulation," T G Gutowski, editor, in Manufacturing International 88, The Manufacturing Science of Composites,Proc ASME WAM , Atlanta, GA , IV49 -56
15.
Meade, L.E.1979. "Fabrication of Thick Graphite/Epoxy Wing Surface Structures," In Proceedings, 24th National SAMPE Svmposium and Exhibition, Book1
16.
Lemtsky, M. and B.W. Shaffer1973 "The Approximation of Temperature Distributions in Homogeneous Exothermic Reactions,"The Chemical Engineering Journal, 5235-242
17.
Wells, G.M. and K.F. McAnulty1987 "Computer Aided Filament Winding Using NonGeodesic Trajectories," In Proceedings, 6th International Conference on Composite Materials , 2nd European Conference on Composite Materials, ICCM & ECCM, 1:1.161-1 173
18.
Beyeler, E.P. and S.I. Guçen.1988 "Thermal Analysis of Laser-Assisted Thermoplastic-Matnx Composite Tape Consolidation," ASME Journal of Heat Transfer, 110424-430.
19.
Ghasemi Nejhad, M.N. , R.D. Cope and S.I. Guçeri1991 " Thermal Analysis of In-Situ Thermoplastic Composite Tape Laying," Journal of Thermoplastic Composite Materials, 4.20-45.
20.
Ghasemi Nejhad, M.N. , R.D. Cope and S.I. Guçeri1991 " Thermal Analysis of In-Situ Thermoplastic Composite Filament Winding," ASME Journal of Heat Transfer, 113.304-313
21.
Ghasemi Nejhad, M.N., R.D. Cope and S.I. Guqen "Effects of Preheating on In-Situ Thermoplastic Composite Tape Laying," To appear in the Journal of Thermoplastic Composite Materials.
