Feasibility Study for Manufacturing CF/Epoxy – Thermoplastic Hybrid Structures in a Single Operation

Kazan, Hakan; Farahani, Saeed; Pilla, Srikanth

doi:10.1016/j.promfg.2019.04.028

Cited by 16 publications

(9 citation statements)

References 7 publications

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“…The experiments of this study were designed based on Taguchi L9 orthogonal array as presented in Table 2. Based on our previous studies related to the HSS method, [21][22][23] the three most influential process settings, that is, pre-heating time, injection temperature, and injection rate, were considered as the varying factors with three levels of variations for each one. The rest of the process settings was considered identical for all the experiment as listed in Table 3.…”

Section: Materials and Proceduresmentioning

confidence: 99%

“…Besides, bonding between the prepreg sheets and the injected thermoplastics occurs with the aid of the prepreg tackiness and the mechanical interlock created by the penetration of the molten polymer. Although the results of the initial feasibility study 21 were promising, some practical issues, such as excessive penetration, insufficient deformation, and weak bonding, were also observed. Hence, the next study was aimed to optimize the process parameters to overcome the aforementioned issues.…”

Section: Introductionmentioning

confidence: 99%

“…20 Similar to the PIF process, the hybrid single shot (HSS) method has been recently introduced based on the integration of thermoforming and injection molding processes. 21 In this process, as thermoset prepreg sheets are inserted and processed instead of sheet metals, a pre-heating stage is also included in this manufacturing approach to promote the curing process. Besides, bonding between the prepreg sheets and the injected thermoplastics occurs with the aid of the prepreg tackiness and the mechanical interlock created by the penetration of the molten polymer.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Experimental analysis on the bonding conditions of thermoset-thermoplastic composite parts manufactured by the hybrid single shot method

Kazan

Farahani

Zheng

et al. 2021

Journal of Composite Materials

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The hybrid single shot method is an innovative manufacturing technique that allows thermoset composite sheets to be formed and cured while they are also bonded into an injected thermoplastic body all in a single integrated operation. This integration concept is complex in nature but promising to overcome the drawbacks of the traditional procedures for manufacturing such multi-material structures by reducing the cycle time, energy consumption, and cost of the required tools and machinery. In this study, CF/Epoxy prepreg sheets are selected as the inserted material which is then later deformed and bonded to an injected body made of a polypropylene compound. The bonding between these two dissimilar materials is mostly achieved by taking the advantages of the melt penetration and the tackiness of the prepreg sheet. Therefore, an experimental study is here designed and carried out to evaluate the bonding conditions of the final hybrid parts regarding several influential process parameters. To better monitor the process and analyze the physics behind this integration, a set of real-time process variables are measured and analyzed using an instrumented experimental setup. The results show that the pre-heating time has the largest effect on the bonding strength, and the best combination of the deformation and bonding strength is achieved when the cavity pressure and temperature are at the highest level compared to the other experiments. The maximum bonding strength attained in the optimum process settings was 6.8 MPa which shows a 51% improvement compared to the average value of the other experiments.

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Section: Materials and Proceduresmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Experimental analysis on the bonding conditions of thermoset-thermoplastic composite parts manufactured by the hybrid single shot method

Kazan

Farahani

Zheng

et al. 2021

Journal of Composite Materials

Self Cite

View full text Add to dashboard Cite

show abstract

“…The innovative thermoforming process has been recently developed to form composite sheets by means of polymer melt pressure during the injection phase [6]. This process is an integration of the thermoforming and injection molding processes and can result in significant reductions of tooling, machinery, and operational cost [7]. In general, the extruded polymer sheets used in thermoforming exhibit anisotropic stresses along the machine direction or in the transverse direction.…”

Section: Literature Reviewmentioning

confidence: 99%

Rheological measurement of the nonlinear viscoelasticity of the ABS polymer and numerical simulation of thermoforming process

Cha

Song

Hyun

et al. 2020

Int J Adv Manuf Technol

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The thickness distribution of thermoformed products is greatly affected by the viscoelastic behavior of the extruded polymer sheet. In this work, linear and nonlinear rheological experiments are carried out to characterize the viscoelastic properties of acrylonitrile-butadiene-styrene sheets under thermoforming conditions including a wide range of temperatures, strains, and strain rates. First, aspects of linear viscoelasticity such as the storage modulus and loss modulus are measured by small-amplitude oscillatory shear experiments. The discrete relaxation spectra and the Williams-Landel-Ferry parameters are obtained from the constructed linear master curves. Then, nonlinear time-dependent extensional viscosity is measured by uniaxial extensional experiments. The parameters of the damping function are evaluated using an optimization method. In addition, the effect of the orientation of the polymer is analyzed. The uniaxial extensional stress and viscosity in the extruder direction demonstrate higher resistance against tearing and extreme thickness reduction during processing. Finally, the linear and nonlinear input parameters for the numerical simulation are prepared. Numerical simulations are performed using the Wagner model with the obtained nonlinear viscoelasticity. The thickness distribution in thermoformed ABS sheets, obtained numerically, shows good agreement with the experimentally obtained values.

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“…Especially, in the field of composite manufacturing, virtual process chains are important to predict structural properties [15]. Furthermore, detailed simulations allow the prediction of internal temperature distributions that can hardly be measured to ensure the required temperature conditions during manufacturing [16,17]. Since these simulations are usually time consuming and expensive to evaluate [18], a real-time suitable surrogate model is needed for virtual quality control to stay computational feasible.…”

Section: Introductionmentioning

confidence: 99%

Machine learning and simulation-based surrogate modeling for improved process chain operation

Hürkamp

Gellrich

Dér

et al. 2021

Int J Adv Manuf Technol

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In this contribution, a concept is presented that combines different simulation paradigms during the engineering phase. These methods are transferred into the operation phase by the use of data-based surrogates. As an virtual production scenario, the process combination of thermoforming continuous fiber-reinforced thermoplastic sheets and injection overmolding of thermoplastic polymers is investigated. Since this process is very sensitive regarding the temperature, the volatile transfer time is considered in a dynamic process chain control. Based on numerical analyses of the injection molding process, a surrogate model is developed. It enables a fast prediction of the product quality based on the temperature history. The physical model is transferred to an agent-based process chain simulation identifying lead time, bottle necks and quality rates taking into account the whole process chain. In the second step of surrogate modeling, a feasible soft sensor model is derived for quality control over the process chain during the operation stage. For this specific uses case, the production rejection can be reduced by 12% compared to conventional static approaches.

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Feasibility Study for Manufacturing CF/Epoxy – Thermoplastic Hybrid Structures in a Single Operation

Cited by 16 publications

References 7 publications

Experimental analysis on the bonding conditions of thermoset-thermoplastic composite parts manufactured by the hybrid single shot method

Experimental analysis on the bonding conditions of thermoset-thermoplastic composite parts manufactured by the hybrid single shot method

Rheological measurement of the nonlinear viscoelasticity of the ABS polymer and numerical simulation of thermoforming process

Machine learning and simulation-based surrogate modeling for improved process chain operation

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