Virtual Manufacturing of Composite Structures Applying Implicit and Explicit FE Techniques

Virtual manufacturing of composites can yield an initial early estimation of the induced residual thermal stresses that affect component fatigue life, and deformations that affect required tolerances for assembly. Based on these estimation, the designer can make early decisions, which can help in reducing cost, regarding changes in part design or material properties. In this paper, an approach is proposed to simulate the autoclave manufacturing technique for unidirectional composites. The proposed approach consists of three modules. The first module is a Thermochemical model to estimate temperature and the degree of cure distributions in the composite part during the cure cycle. The second and third modules are stress analysis using FE-Implicit and FE-Explicit respectively. User-material subroutine will be used to model the Viscoelastic properties of the material based on micromechanical theory. Estimated deformation of the composite part can be corrected during the autoclave process by modifying the process-tool design. The deformed composite surface is sent to CATIA for design modification of the process-tool.

Separate Density and Viscosity Determination of Room Temperature Ionic Liquids using Dual Quartz Crystal Microbalances

The drive towards cleaner industrial processes has led to the development of room temperature ionic liquids (RTIL) as environmentally friendly solvents. They comprise solely of ions which are liquid at room temperature and with over one million simple RTIL alone it is important to characterize their physical properties using minimal sample volumes. Here we present a dual Quartz Crystal Microbalance (QCM) which allows separate determination of viscosity and density using a total sample volume of only 240 mu L. Liquid traps were fabricated on the sensing area of one QCM using SU-8 10 polymer with a second QCM having a flat surface. Changes in the resonant frequencies were used to extract separate values for viscosity and density. Measurements of a range of pure RTIL with minimal water content have been made on five different trap designs. The best agreement with measurements from the larger volume techniques was obtained for trap widths of around 50 pm thus opening up the possibility of integration into lab-on-a-chip systems.

Investigation of the temperature homogeneity of die melt flows in polymer extrusion

Polymer extrusion is fundamental to the processing of polymeric materials and melt flow temperature homogeneity is a major factor which influences product quality. Undesirable thermal conditions can cause problems such as melt degradation, dimensional instability, weaknesses in mechanical/optical/geometrical properties, and so forth. It has been revealed that melt temperature varies with time and with radial position across the die. However, the majority of polymer processes use only single-point techniques whose thermal measurements are limited to the single point at which they are fixed. Therefore, it is impossible for such techniques to determine thermal homogeneity across the melt flow. In this work, an extensive investigation was carried out into melt flow thermal behavior of the output of a single extruder with different polymers and screw geometries over a wide range of processing conditions. Melt temperature profiles of the process output were observed using a thermocouple mesh placed in the flow and results confirmed that the melt flow thermal behavior is different at different radial positions. The uniformity of temperature across the melt flow deteriorated considerably with increase in screw rotational speed while it was also shown to be dependent on process settings, screw geometry, and material properties. Moreover, it appears that the effects of the material, machine, and process settings on the quantity and quality of the process output are heavily coupled with each other and this may cause the process to be difficult to predict and variable in nature