Experimental investigation of thermoforming carbon fibre-reinforced polyphenylene sulphide composites

Pre-consolidated carbon fibre-reinforced polyphenylene sulphide (CF/PPS) laminates were
thermoformed into V-shaped parts via designed out of autoclave thermoforming experiments.
The different processing conditions tested in the experiment have resulted in final
part angles whose differences ranged from 2.087 to 3.431 from the original mould angle.
The test results show that processing conditions influenced finished part dimensions as the
final sample angles were found to decrease relative to the tooling dimensions, as mould
temperature increases. Higher mould temperature conditions produce thinner parts due
to the thermal expansion of mould tools. The mould temperature of 170C, which can
produce parts with high degree of crystallinity as well as small size of crystal, has been
established as the optimal thermoforming condition for CF/PPS composites.

Numerical investigation of the effects of drill geometry on drilling induced delamination of carbon fiber reinforced composites

Drilling is a major process in the manufacturing of holes required for the assemblies of composite laminates in aerospace industry. Simulation of drilling process is an effective method in optimizing the drill geometry and process parameters in order to improve hole quality and to reduce the drill wear. In this research we have developed three-dimensional (3D) FE model for drilling CFRP. A 3D progressive intra-laminar failure model based on the Hashin's theory is considered. Also an inter-laminar delamination model which includes the onset and growth of delamination by using cohesive contact zone is developed. The developed model with inclusion of the improved delamination model and real drill geometry is used to make comparison between the step drill of different stage ratio and twist drill. Thrust force, torque and work piece stress distributions are estimated to decrease by the use of step drill with high stage ratio. The model indicates that delamination and other workpiece defects could be controlled by selection of suitable step drill geometry. Hence the 3D model could be used as a design tool for drill geometry for minimization of delamination in CFRP drilling. © 2013 Elsevier Ltd.

The effect of 3D weaving and consolidation on carbon fiber tows, fabrics, and composites

This article investigates the damage imparted on load-bearing carbon fibers during the 3D weaving process and the subsequent compaction behavior of 3D woven textile preforms. The 3D multi-layer reinforcements were manufactured on a textile loom with few mechanical modifications to produce preforms with fibers orientated in the warp, weft, and through-the-thickness directions. Tensile tests were conducted on three types of commercially available carbon fibers, 12k HTA, 6k HTS, and 3k HTS in an attempt to quantify the effect of fiber damage induced during the 3D weaving process on the mechanical and physical performance of the fiber tows in the woven composite. The tests were conducted on fiber tows sampled from different locations in the manufacturing process from the bobbin, through the creel and loom mechanism, to the final woven fabric. Mechanical and physical testing were then conducted to quantify the tow geometry, orientation and the effect of compaction during manufacture of two styles of 3D woven composite by vacuumassisted resin transfer molding (VaRTM).

Modeling the geometric characteristics of five-dimensionally woven composites

An analytical modeling approach for the prediction of the geometric characteristics of five-dimensional (5D) woven composites has been formulated. The model is driven by readily available data including the weaving parameters and constituent material properties. The new model calculates the individual proportions of fiber in each direction, areal density, overall fiber volume fraction, and laminate thickness. This information is useful for the engineer in the design and manufacture of 5D woven composites. In addition the present model outputs the mathematical definition of the 5D woven composite unit cell, which could be implemented as the geometric input for a downstream analytical model that is capable of predicting the elastic stiffness of 5D woven composites. Input parameters have been sourced from existing published work and the subsequent predictions made by the model are compared with the available experimental data on 5D woven composites.

Performance of calcium deficient hydroxyapatite-polyglycolic acid composites: An in vitro study

The strategic incorporation of bioresorbable polymeric additives to calcium-deficient hydroxyapatite cement may provide short-term structural reinforcement and modify the modulus to closer match bone. The longer-term resorption properties may also be improved, creating pathways for bone in-growth. The aim of this study was to investigate the resorption process of a calcium phosphate cement system containing either in polyglycolic acid tri-methylene carbonate particles or polyglycolic acid fibres. This was achieved by in vitro aging in physiological conditions (phosphate buffered solution at 37°C) over 12 weeks. The unreinforced CPC exhibited an increase in compressive strength at 12 weeks, however catastrophic failure was observed above a critical loading. The fracture behaviour of cement was improved by the incorporation of PGA fibres; the cement retained its cohesive structure after critical loading. Gravimetric analysis and scanning electron microscopy showed a large proportion of the fibres had resorbed after 12 weeks allowing for the increased cement porosity, which could facilitate cell infiltration and faster integration of natural bone. Incorporating the particulate additives in the cement did not provide any mechanism for mechanical property augmentation or did not demonstrate any appreciable level of resorption after 12 weeks.