Compressible Constrained Layer Damping (CCLD) is a novel, semi-active, lightweight-compatible solution for vibration mitigation based on the well-known constrained layer damping principle. The sandwich-like CCLD set-up consists of a base structure, a constraining plate, and a compressible open-cell foam core in between, enabling the adjustment of the structure’s vibration behaviour by changing the core compression using different actuation pressures. The aim of the contribution is to show to what degree, and in which frequency range the acoustic behaviour can be tuned using CCLD. Therefore, the sound transmission loss (TL), as an important vibro-acoustic index, is determined in an acoustic window test stand at different actuation pressures covering a frequency range from 0.5 to 5 kHz. The different actuation pressures applied cause a variation of the core layer thickness (from 0.9 d0 to 0.3 d0), but the resulting changes of the stiffness and damping of the overall structure have no significant influence on the TL up to approximately 1 kHz for the analysed CCLD design. Between 1 kHz and 5 kHz, however, the TL can be influenced considerably well by the actuation pressure applied, due to a damping-dominated behaviour around the critical frequency.
The economical production of lightweight structures with tailor-made properties and load-adapted geometry is limited using conventional technologies. Additive manufacturing processes offer a high potential to meet these requirements, where the established solutions are based primarily on thermoplastics matrix systems. From a process-technological point of view, thermoplastics enable simplified processing, but only a limited range of applications for high-performance components. These limitations are due to their comparatively low heat resistance, low melting temperatures and limited adhesion to embedded reinforcing fibers. In contrast, thermosets show high potential for realization of high- performance lightweight structures with adaptable properties. The present work employs a UV-curing thermoset resin for the impregnation of a continuous filament strand for 3D printing. The main challenge is to reconcile the crosslinking reaction of the thermoset and the process velocity during impregnation and cure. The liquid polymer must provide low initial viscosity to impregnate the filaments and a sufficiently high cure rate and dimensional stability after discharge from the print head to ensure sufficient bonding strength to the substrate. To demonstrate feasibility, a prototypic print head with UV-LED activation was designed and implemented. With a robot-guided printing platform, the 3D-deposition of continuous fiber-reinforcements without additional supporting structures can be realized. To derive initial process parameters, reaction and thermos-mechanical properties are determined by rheometer measurements. Impregnation and cure behavior of the glass fiber reinforced resin is investigated. The presented results provide a reliable process window and a straightforward process monitoring method for further enhancement of the conceived 3D printing process.
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