Optimization of a Pultrusion Process Using Finite Difference and Particle Swarm Algorithms

Abstract

-Pultrusion is one of several manufacturing processes for reinforced polymer composites. In this process fibers are continuously pulled through a resin bath and, after impregnation, the fiber-resin assembly is cured in a heated forming die. In order to obtain a polymeric composite with good properties (high and uniform degree of cure) and a process with a minimum of wasted energy, an optimization procedure is necessary to calculate the optimal temperature profile. The present work suggests a new strategy to minimize the energy rate taking into account the final quality of the product. For this purpose the particle swarm optimization (PSO) algorithm and the computer code DASSL were used to solve the differential algebraic equation that represents the mathematical model. The results of the optimization procedure were compared with results reported in the literature and showed that this strategy may be a good alternative to find the best operational point and to test other heat policies in order to improve the material quality and minimize the energy cost. In addition, the robustness and fast convergence of the algorithm encourage industrial implementation for the inference of the degree of cure and optimization.

Numerical optimisation of thermoset composites manufacturing processes: A review

“…A zero order search algorithm has been adopted and combined with a gradient based technique in a hybrid scheme to optimise the pulling speed and the temperature profile achieving a reduction in process cost of about 30% [73]. The objective of energy consumption minimisation has also been tackled to reduce process cost [74,75]. The optimisation sought optimal die temperatures to minimise energy consumption in a dual die pultrusion process, whilst the quality of the manufactured parts was ensured by applying a minimum degree of cure variation across the thickness allowed.…”

“…The optimisation sought optimal die temperatures to minimise energy consumption in a dual die pultrusion process, whilst the quality of the manufactured parts was ensured by applying a minimum degree of cure variation across the thickness allowed. A swarm particle algorithm was adopted for SO optimisation showing that it is possible to minimise energy consumption by lowering the temperature of the second heater and exploiting the heat released by the cure reaction triggered with the first heater temperature achieving a 25% reduction in energy consumption compared to a standard process [74,75]. Cure cycle optimisation has been carried out under uncertainty showing that minimum cure time increases when variability is taken into account [76,77].…”

Optimization of Kinetic Lumping Model Parameters to Improve Products Quality in the Hydrocracking Process

“…In the present work, a PSO algorithm has been applied for the parameter optimization. This method has many advantages including: fast convergence, finding the global optimum in the presence of many local optima, and simple programming (Shokri et al, 2014;Santos et al, 2015). Figure 1 shows a flowchart for the optimization mode of the program.…”

Analysis of Composite Material Properties and Their Possibilities to Use Them in Bus Frame Construction

“…ity to combine high-speed production with high-quality parts produced. Moreover, in order to obtain a polymer composition with good properties (high and uniform degree of cure) and a process with minimal energy consumption, it is necessary to calculate the optimum temperature profile (Santos et al 2015). So, this high-quality pultruded fiberglass tube can be used in bus safety construction.…”