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Simulation of Kiss-Roll Coating
This thesis shall build on an existing simulation tool in ANSYS Fluent which models dip-coating of single fibers for the production of bicomponent fibers. The model geometry shall be modified to resemble kiss-roll coating of a single fiber.
Today, fiber-reinforced composites are broadly considered to be lightweight but labor intensive alternatives to conventional engineering materials and are thus seldom chosen for high volume production schemes. Let’s change that!
Composites with thermoplastic matrix systems offer alternative processing routes and provide a higher potential for recyclability than those containing conventional thermosets. However, the desired low cycle times are currently only achievable in stamp forming using comparatively expensive organosheets. Stamp forming of thermoplastic composites is still a promising method for high volume production and facilitates the transition of using composite materials in existing sheet press plants. The issue at hand lies not with the process, but with the intermediate material.
**Thermoplastic Sheath Bicomponent Fibers**
The concept of providing continuous reinforcement fibers which are individually coated with a thermoplastic as a bicomponent intermediate material for stamp forming fills that gap, because the composite has a complete wet-out to begin with and only needs to be consolidated.
The fabrication of such bicomponent fibers is not trivial. CMASLab investigates high-speed coating processes based on dilute polymer solutions as methods of manufacture.
Today, fiber-reinforced composites are broadly considered to be lightweight but labor intensive alternatives to conventional engineering materials and are thus seldom chosen for high volume production schemes. Let’s change that!
Composites with thermoplastic matrix systems offer alternative processing routes and provide a higher potential for recyclability than those containing conventional thermosets. However, the desired low cycle times are currently only achievable in stamp forming using comparatively expensive organosheets. Stamp forming of thermoplastic composites is still a promising method for high volume production and facilitates the transition of using composite materials in existing sheet press plants. The issue at hand lies not with the process, but with the intermediate material.
**Thermoplastic Sheath Bicomponent Fibers** The concept of providing continuous reinforcement fibers which are individually coated with a thermoplastic as a bicomponent intermediate material for stamp forming fills that gap, because the composite has a complete wet-out to begin with and only needs to be consolidated.
The fabrication of such bicomponent fibers is not trivial. CMASLab investigates high-speed coating processes based on dilute polymer solutions as methods of manufacture.
This thesis shall build on an existing simulation tool in ANSYS Fluent which models dip-coating of single fibers for the production of bicomponent fibers. The model geometry shall be modified to resemble kiss-roll coating of a single fiber.
The existing model employs the volume of fluid (VOF) method to solve the Navier-Stokes equation for an immiscible two-phase (fluid/gas) system and find the interface of the two phases. The current model is highly depending on mesh quality while using the mesh generator of ANSYS Workbench. For this project and future work, a mesh generation routine in ICEM shall be implemented.
**Your Profile**
- Interested in modeling and simulation work
- Ideally experience with ANSYS Fluent/ICEM, or other CFD software
Content may be discussed to also suit a semester thesis.
Co-supervision by or general cooperation with the Institute of Fluid Dynamics at ETHZ are welcome.
This thesis shall build on an existing simulation tool in ANSYS Fluent which models dip-coating of single fibers for the production of bicomponent fibers. The model geometry shall be modified to resemble kiss-roll coating of a single fiber.
The existing model employs the volume of fluid (VOF) method to solve the Navier-Stokes equation for an immiscible two-phase (fluid/gas) system and find the interface of the two phases. The current model is highly depending on mesh quality while using the mesh generator of ANSYS Workbench. For this project and future work, a mesh generation routine in ICEM shall be implemented.
**Your Profile** - Interested in modeling and simulation work - Ideally experience with ANSYS Fluent/ICEM, or other CFD software
Content may be discussed to also suit a semester thesis. Co-supervision by or general cooperation with the Institute of Fluid Dynamics at ETHZ are welcome.
ETH Zurich
Christoph Schneeberger
CLA E 32.2
Tannenstrasse 3
8092 Zurich
Phone: +41 44 633 63 08
cschneeb@ethz.ch
www.structures.ethz.ch
ETH Zurich Christoph Schneeberger CLA E 32.2 Tannenstrasse 3 8092 Zurich