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 elimination of the curing steps that are necessary in the processing of thermoset-matrix composites. This paper discusses analytical and numerical anisotropic thermal analysis for preheating and/or pultrusion of impregnated composite tows or tapes. Heat of melting/solidification is included in the form of a heat generation term. A separation of variable method is employed to solve the governing equations analytically. In the numerical analysis, the governing equations are discretized using a nonuniform mesh and solved employing a finite difference approach. The processing parameters, such as processing speed, heat intensity, heat source width, etc., as well as material properties are incorporated in the analysis. The maximum error between the analytical solution and the numerical result is found to be 1%.
References
1.
1. Chang, I. Y. and J. K. Lees. 1988. "Recent Developments in Thermoplastic Composites: A Review of Matrix Systems and Processing Methods,"Journal of Thermoplastic Composite Materials, 1: 304-313.
2.
2. Chang, I. Y. 1992. "Thermoplastic Matrix Composites Development Update," in Proceedings, 37th International SAMPE Symposium, Anaheim, CA, 37:1276-1290.
3.
3. Lee, S. M., Ed. 1993. Handbook of Composite Reinforcements, VCH Publishers, New York.
4.
4. Pitchumani, R., S. Ranganathan, R. C. Don, J. W. Gillespie, Jr. and M. A. Lamontia. 1996. 'Analysis of Transport Phenomena Governing Interfacial Bonding and Void Dynamics during Thermoplastic Tow-Placement,"International Journal of Heat and Mass Transfer, 39(9):1883-1897.
5.
5. Pitchumani, R., J. W. Gillespie, Jr. and M. A. Lamontia. 1997. "Design and Optimization of Thermoplastic Tow-Placement Process,"Journal of Composite Materials, in press.
6.
6. Ghasemi Nejhad, M. N. 1992. "Three-Dimensional Thermal and Residual Stress Analysis of insitu Thermoplastic Composite Filament Winding," Ph.D. dissertation, Department of Mechanical Engineering, University of Delaware, Newark, Delaware.
7.
7. Ghasemi Nejhad, M. N., J. W. Gillespie, Jr. and R. D. Cope. 1992. "Prediction of Process-Induced Stresses for insitu Thermoplastic Filament Winding of Cylinders,"Proceedings of Third International Conference CADCOMP 92 Computer Aided Design in Composite Material Technology, pp. 225-253.
8.
8. Ghasemi Nejhad, M. N., J. W. Gillespie, Jr. and R. D. Cope. 1992. "Processing Stresses for insitu Thermoplastic Filament Winding Using the Divergence Method,"Proceedings of ASME Winter Annual Meeting 1992, Heat Transfer Effects in Materials Processing, Guqeri, S. I. and Alam, M. K., Eds., American Society of Mechanical Engineers, HTD-233:33-43.
9.
9. Wang, E. and T. Gutowski. 1990. "Cost Comparison Between Thermoplastic and Thermoset Composites,"SAMPE Journal, 16(6):19-26.
10.
10. Griffiths, G. R., W. D. Hillier and J. A. S. Whiting. 1988. "Thermoplastic Composite Manufacturing Technology for a Flight Standard Tailplane," in Proceedings, 33rd International SAMPE Symposium, Anaheim, CA, 33:308-316.
11.
11. Beyeler, E. P., W. Phillips and S. I. Gueri. 1988. "Experimental Investigation of Laser-Assisted Thermoplastic Tape Consolidation,"Journal of Thermoplastic Composite Materials, 1:107-121.
12.
12. Beyeler, E. P. and S. I. Guqeri. 1988. "Thermal Analysis of Laser-Assisted Thermoplastic-Matrix Composite Tape Consolidation,"ASME Journal of Heat Transfer, 110:424-430.
13.
13. Gilmore, S. D. 1991. "Thermal and Residual Stress Analysis in Processing of Thermoplastic Composites," Ph.D. dissertation, Department of Mechanical Engineering, University of Delaware, Newark, DE.
14.
14. Hollingsworth, R. D. and D. R. Osment. 1987. "Filament Wound Thermoplastic Matrix Pressure Vessels," in Proceedings, 32nd International SAMPE Symposium, Anaheim, CA, 32:662-669.
15.
15. Winkel, J. D. and J. R. Hurdle. 1988. "Mechanical Performance of Filament Wound Polyphenylene Sulfide Thermoplastic Composite Tubular Structures," in Proceedings, 33rd International SAMPE Symposium, Anaheim, CA, 33:816-828.
16.
16. Egerton, M. W. and M. B. Gruber. 1988. "Thermoplastic Filament Winding Demonstrating Economics and Properties via insitu Consolidation," in Proceedings, 33rd International SAMPE Symposium, Anaheim, CA, 33:35-46.
17.
17. Egerton, M. W. and M. B. Gruber. 1989. "Thermoplastic Filament Wound Parts Demonstrating Properties in Crush Tube and Torque Tube Applications," in Proceedings, 34th International SAMPE Symposium, Reno, NV, 34:159-170.
18.
18. Werderman, C., K. Friedrich, M. Cirino and R. B. Pipes. 1989. "Design and Fabrication of an On-Line Consolidation Facility for Thermoplastic Composites,"Journal of Thermoplastic Composite Materials, 2:293-306.
19.
19. Hummler, J., S. K. Lee and K. V. Steiner. 1991. "Recent Advances in Thermoplastic Robotic Filament Winding," Technical Report CCM-91-06, Center for Composite Materials Report, University of Delaware, Newark, DE.
20.
20. Calius, E. P. and G. S. Springer. 1988. "Filament Winding Process Simulation,"T. G. Gutowski, editor, in Manufacturing International '88. The Manufacturing Science of Composites, Proc. ASME WAM, Atlanta, GA, IV:49-56.
21.
21. Meade, L. E. 1979. "Fabrication of Thick Graphite/Epoxy Wing Surface Structures," in Proceedings, 24th National SAMPE Symposium and Exhibition, Book I.
22.
22. Levitsky, M. and B. W. Shaffer. 1973. "The Approximation of Temperature Distributions in Homogeneous Exothermic Reactions,"The Chemical Engineering Journal, 5:235-242.
23.
23. Wells, G. M. and K. F. McAnulty. 1987. "Computer Aided Filament Winding Using NO-Geodesic Trajectories," in Proceedings, 6th International Conference on Composite Materials, 2nd European Conference on Composite Materials, ICCM & ECCM, 1:1.161-1.173.
24.
24. Ghasemi Nejhad, M. N., R. D. Cope and S. I. Guqeri. 1991. "Thermal Analysis of insitu Thermoplastic-Matrix Composite Filament Winding,"ASME Journal of Heat Transfer, 113:304-313.
25.
25. Ghasemi Nejhad, M. N., R. D. Cope and S. I. Guqeri. 1991. "Thermal Analysis of insitu Thermoplastic Composite Tape Laying,"Journal of Thermoplastic Composite Materials, 4(1):20-45.
26.
26. Ghasemi Nejhad, M. N.1993. "Issues Related to Processability during the Manufacturing of Thermoplastic Composites Using On-Line Consolidation Techniques,"Journal of Thermoplastic Composite Materials, 6(2):130-146.
27.
27. Ghasemi Nejhad, M. N., J. W. Gillespie, Jr. and R. D. Cope. 1994. "Effects of Processing Parameters on Material Responses during insitu Filament Winding of Thermoplastic Composites,"International Journal of Materials and Product Technology, Concurrent Engineering of Advanced Materials-Integration of Mechanics and Manufacturing, 9(1/2/3):183-214.
28.
28. Astrom, B. T.1991. 'Analysis of Manufacturing Methods for Thermoplastic Matrix Composites," Report No. 91-24, Department of Aeronautical Structures and Materials, The Royal Institute of Technology, Stockholm, Sweden.
29.
29. Astrom, B. T., P. H. Larsson and R. B. Pipes. 1991. "Experimental Investigation of a Thermoplastic Pultrusion Process," in Proceedings, 36th International SAMPE Symposium, Anaheim, CA, 36:1319-1330.
30.
30. Lee, W. I., G. S. Springer and F. N. Smith. 1991. "Pultrusion of Thermoplastics," in Proceedings, 36th International SAMPE Symposium, Anaheim, CA, 36:1309-1318.
31.
31. Seymour, R. J. and F. E. Sloan. 1991. "Pultrusion and Thermoforming of a Graphite-Reinforced-Thermoplastic Marine Cable," in Proceedings, 36th International SAMPE Symposium, Anaheim, CA, 36:1331-1341.
32.
32. Cho, B. G., S. P. McCarthy, J. P. Fanucci and S. C. Nolet. 1992. "Performance of Nylon-6 Composites Produced by the Reaction Injection Pultrusion Process," in Proceedings, 24th International SAMPE Technical Conference, 24:T645-T659.
33.
33. Astrom, B. T., P. H. Larsson and R. B. Pipes. 1991. "Development of a Facility for Pultrusion of Thermoplastic-Matrix Composites,"Composites Manufacturing, 2(2):114-123.
34.
34. Astrom, B. T.1992. "Development and Application of a Process Model for Thermoplastic Pultrusion,"Composites Manufacturing, 3(3):189-197.
35.
35. Astrom, B. T. and R. B. Pipes. 1993. "Modeling Approach to Thermoplastic Pultrusion. I. Formulation of Models."Polymer Composites, 14(3):173-183.
36.
36. Astrom, B. T. and R. B. Pipes. 1993. "Modeling Approach to Thermoplastic Pultrusion. II. Verification of Models,"Polymers Composites, 14(3):184-194.
37.
37. Astrom, B. T., P. H. Larsson, P. J. Hepola and R. B. Pipes. 1994. "Flexural Properties of Pultruded Carbon/PEEK Composites as a Function of Processing History,"Composites, 25(8):814-821.
38.
38. Carlsson, A. and B. T. Astrom. 1996. "Modeling of Heat Transfer and Crystallization Kinetics in Thermoplastic Pultrusion," in Proceedings, 41st International SAMPE Symposium, Anaheim, CA, 41:1324-1334.
