Process Modeling in Composites Manufacturing, Second Edition

There is a wealth of literature on modeling and simulation of polymer composite manufacturing processes. However, existing books neglect to provide a systematic explanation of how to formulate and apply science-based models in polymer composite manufacturing processes. Process Modeling in Composites Manufacturing, Second Edition provides tangible methods to optimize this process — and it remains a proven, powerful introduction to the basic principles of fluid mechanics and heat transfer.

Building on past developments, this new book updates the previous edition’s coverage of process physics and the state of modeling in the field. Exploring research derived from experience, intuition, and trial and error, the authors illustrate a state-of-the-art understanding of mass, momentum, and energy transfer during composites processing. They introduce computer-based solutions using MATLAB® code and flow simulation-based analysis, which complement closed-form solutions discussed in the book, to help readers understand the role of different material, geometric, and process parameters.

This self-contained primer provides an introduction to modeling of composite manufacturing processes for anyone working in material science and engineering, industrial, mechanical, and chemical engineering. It introduces a scientific basis for manufacturing, using solved example problems which employ calculations provided in the book. End-of-chapter questions and problems and fill in the blanks sections reinforce the content in order to develop the experience base of the manufacturing, materials, and design engineer or scientists, as well as seniors and first-year graduate students.

Includes tools to develop an experience base to aid in modeling a composite manufacturing process

INTRODUCTION

Motivation and Contents

Preliminaries

Polymer Matrices for Composites

Fibers

Classification

General Approach to Modeling

Organization of the Book

OVERVIEW OF MANUFACTURING PROCESSES

Background

Classification Based on Dominant Flow Process

Short Fiber Suspension Manufacturing Methods

Advanced Thermoplastic Manufacturing Methods

Advanced Thermoset Composite Manufacturing Methods

TRANSPORT EQUATIONS FOR COMPOSITE PROCESSING

Introduction to Process Models

Conservation of Mass (Continuity Equation)

Conservation of Momentum (Equation of Motion)

Stress-Strain Rate Relationship

Examples to Solve Viscous Flow Problems

Conservation of Energy

CONSTITUTIVE LAWS AND THEIR CHARACTERIZATION

Resin Viscosity

Viscosity of Aligned Fiber Thermoplastic Laminates

Suspension Viscosity

Reaction Kinetics

Thermoplastic Reactive Processing

Crystallization Kinetics

Permeability

Fiber Stress

MODEL SIMPLIFICATIONS AND SOLUTION

Formulation of Models

Model and Geometry Simplifications

Dimensionless Analysis and Dimensionless Numbers

Customary Assumptions in Polymer Composite Processing

Boundary Conditions for Flow Analysis

Convection of Variables

Process Models from Simplified Geometries

Mathematical Tools for Simplification

Solution Methods

Numerical Methods

Validation

SHORT FIBER COMPOSITES

Compression Molding

Extrusion

Injection Molding

Exercises

ADVANCED THERMOPLASTIC MANUFACTURING PROCESSES

Composite Sheet Forming Processes

Pultrusion

Thermal Model

Online Consolidation of Thermoplastics

PROCESSING ADVANCED THERMOSET FIBER COMPOSITES

Autoclave Molding

Liquid Composite Molding

Filament Winding of Thermosetting Matrix Composites

Summary and Outlook

MATLAB Files

Solution to Example 8.13 using FDM

Additional Examples with LIMS to Model Liquid Mold Filling

Bibliography

Index