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Development of manufacturing process for large diameter thermoplastic composite profiles
The objective of this thesis is to determine the manufacturing limits for thermoplastic composite profiles. After the design of the appropriate die geometry using FEM and CAD, a demonstrator will prove the feasibility of the concept.
Keywords: thermoplastic, pultrusion, composite, high peformance,
Thermoplastic pultrusion is one of the most promising manufacturing techniques for high quality, high performance composites at a competitive cost. In this joint research project with the swiss industry, a novel pultrusion concepts has been developed at CMASLab, which is currently able to manufacture rods up to Ø20mm. As the current process consists of melting polymer fibres mixed with reinforcing fibres in a circular die to impregnate the material and then cool the composite rod from outside until solidification, large residual stresses are expected to occur in the material for larger rod diameters up to Ø 100mm. This could lead to cracks or other defects in the material. To overcome those challenges, a detailed numerical simulation of the manufacturing process is very important to consecutively design the optimum die geometry and prove experimentally that the pultrusion of large diameters is possible.
Thermoplastic pultrusion is one of the most promising manufacturing techniques for high quality, high performance composites at a competitive cost. In this joint research project with the swiss industry, a novel pultrusion concepts has been developed at CMASLab, which is currently able to manufacture rods up to Ø20mm. As the current process consists of melting polymer fibres mixed with reinforcing fibres in a circular die to impregnate the material and then cool the composite rod from outside until solidification, large residual stresses are expected to occur in the material for larger rod diameters up to Ø 100mm. This could lead to cracks or other defects in the material. To overcome those challenges, a detailed numerical simulation of the manufacturing process is very important to consecutively design the optimum die geometry and prove experimentally that the pultrusion of large diameters is possible.
The goal of this thesis is to determine the manufacturin limit for thermoplastic pultrusion. In a first step, the largest possible diameter will be determined through an existing Comsol simulation. IN a second step, an appropriate die geometry will be developed through a combination of CAD and FEM simulation. The last step will consist of experimentally verifying the die design through the pultrusion of large diameter profiles. The pultruded profiles will analysed for their quality in terms of void content and mechanical strength and their properties will be related back to processing parameters such as temperatures and pulling speeds.
Tasks:
- Simulation of manufacturing process (existing Comsol FEM model)
- Development of die geometry in Siemens NX, creation of drawings to be manufactured
- Assembly of experimental set-up, pultrusion of rods
- Analysis of quality through microscopy, mechanical tests
The content as well as starting dates can be discussed to suit a Masters, Semest
The goal of this thesis is to determine the manufacturin limit for thermoplastic pultrusion. In a first step, the largest possible diameter will be determined through an existing Comsol simulation. IN a second step, an appropriate die geometry will be developed through a combination of CAD and FEM simulation. The last step will consist of experimentally verifying the die design through the pultrusion of large diameter profiles. The pultruded profiles will analysed for their quality in terms of void content and mechanical strength and their properties will be related back to processing parameters such as temperatures and pulling speeds.
Tasks:
- Simulation of manufacturing process (existing Comsol FEM model) - Development of die geometry in Siemens NX, creation of drawings to be manufactured - Assembly of experimental set-up, pultrusion of rods - Analysis of quality through microscopy, mechanical tests
The content as well as starting dates can be discussed to suit a Masters, Semest