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Investigation of manufacturing limits of large cross-section thermoplastic profiles
The objective of this thesis is the manufacturing feasibility investigation of large diameter, thermoplastic profiles based on the experimental and numerical study of processing conditions and material characteristics of variable diameter rods ranging from Ø5 to Ø20 mm.
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 concept has been developed at CMASLab, which is currently able to manufacture rods up to Ø20mm, with larger diameters under development. The process currently consists of melting polymer fibers mixed with reinforcing fibers by pulling them through a circular die to impregnate the material and then cool the composite rod from outside until solidification, For the intended application of the composite rods as ultra-high voltage insulators with diameters up to Ø200, it is crucial to predict processing parameters and material characteristics such as pulling forces, manufacturing speeds and void contents.
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 concept has been developed at CMASLab, which is currently able to manufacture rods up to Ø20mm, with larger diameters under development. The process currently consists of melting polymer fibers mixed with reinforcing fibers by pulling them through a circular die to impregnate the material and then cool the composite rod from outside until solidification, For the intended application of the composite rods as ultra-high voltage insulators with diameters up to Ø200, it is crucial to predict processing parameters and material characteristics such as pulling forces, manufacturing speeds and void contents.
The objective of this thesis is to investigate the evolution of different processing parameters (e.g. pulling forces, manufacturing speeds) as well as material characteristics (e.g. void content, crystallinity, residual stresses, mechanical properties) for different rod diameters from Ø5 mm up to Ø20 mm to be able to extrapolate those vales for very large rods. Even though not primary focus of this thesis, an existing thermo-mechanical FEM models will be modified to validate and help understand the effects occurring during the manufacturing of large diameter thermoplastic profiles.
Tasks:
-Experimental study of processing parameters
-Investigation of material parameters
-Adaptation of existing thermo-mechanical FEM model to new conditions and comparison with experimental results
The content as well as starting dates can be discussed to suit a Masters, Semester or Bachelor thesis as well as the personal interests of the student.
The objective of this thesis is to investigate the evolution of different processing parameters (e.g. pulling forces, manufacturing speeds) as well as material characteristics (e.g. void content, crystallinity, residual stresses, mechanical properties) for different rod diameters from Ø5 mm up to Ø20 mm to be able to extrapolate those vales for very large rods. Even though not primary focus of this thesis, an existing thermo-mechanical FEM models will be modified to validate and help understand the effects occurring during the manufacturing of large diameter thermoplastic profiles.
Tasks:
-Experimental study of processing parameters
-Investigation of material parameters
-Adaptation of existing thermo-mechanical FEM model to new conditions and comparison with experimental results
The content as well as starting dates can be discussed to suit a Masters, Semester or Bachelor thesis as well as the personal interests of the student.
Maximilian Volk
LEE O 224, ETH Zürich
mvolk@ethz.ch
0041446326548