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1

Modelling of the Monolithic Stiffener Forming Process from a Peak Thermoplastic Composite Matrix Using Pam-Form Software

Polański Witold

Transactions on Aerospace Research

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2023

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Nr 2 (271)

58--75

EN

The growing use of thermoplastic composites in aviation, automotive, sports and medical industries is forcing the development of processing technology. Due to the properties of thermoplastic composite materials, their shaping is subject to many restrictions. For this reason, it is not always possible to obtain components with complex geometry and adequate quality. By using numerical analysis and experience in the production of parts using hot pressing technology, we are able to predict the course of the process and the behaviour of the material during formation. The article describes how to build a model for numerical analysis of the process of thermoforming monolithic inspection door stiffening for an ILX-34 aircraft using a toray Cetex® TC1225 carbon composite material with a thermoplastic polyaryletherketone (PAEK) matrix. Pam-Form v2019.0 software version V1.9.N was used for modelling. The results of the analysis were compared with those of the part produced by the Institute of Aviation, Łukasiewicz Research Network.

2

Tooling development for thermoplastic composites thermoforming process based on FEM analysis : a rib case study

Dobrzański P., Molak R.

Journal of KONES

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2018

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Vol. 25, No. 4

67--74

EN

Remarkable characteristics of high temperature thermoplastic (HTP) matrix used in composite materials reinforced with continuous fibres causes growing application in composite industry. Because of high processing temperature of some semi, crystalline matrix there is limited number of technologies that can be used for part manufacturing. Press forming is an example of technology that allows manufacturing high quality complex parts made of HTP reinforced fibres composite. In order to manufacture part with acceptable quality and mechanical properties, uniform pressure distribution during the process is required. In this article, tooling design process focused on uniform pressure distribution for manufacturing of supporting rib was presented. In order to satisfy this requirement, the rubber stamp was proposed as a tool for manufacturing. Typical press forming process defects were identified and the requirements for rubber stamp were described. It was assumed that the forming process has to begin at one point on mould surface and sequentially continue in all directions. For stamp material, the two components additive silicone was selected. The hardness of the silicone was equal 40 Shore A. The rubber mechanical properties was determined through the additional tests and used for stamp designing. The tooling was designed using FEM software ABAQUS 6.12. The sequence of stamp shape designing and optimization in order to meet the stamp requirements was presented. At the end the FEM rubber stamp designing recommendation were presented.

3

Milling tools for cutting of fiber-reinforced plastic

Kolar P., Masek P., Zeman P.

Journal of Machine Engineering

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2014

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Vol. 14, No. 2

93--103

EN

Composites with thermoplastic matrix are used in a wide range of applications. Their production and application volume grows every year. The need for precision machining of a near-net-shape workpiece is a topical subject, which concerns many cutting tool developers. The main challenge lies in the combinations of the long tool life and perfectly machined surface of composite workpiece without the burrs or delamination. The fulfilment of these two options needs using of the specific cutting geometry and very stiff and solid material of the cutting tool which is resistant against the abrasion of the filament. This paper presents a case study for comparison of cutting tools for edge trimming operations. The burr size and the tool lifetime were evaluated for milling of two types of fibre reinforced thermoplastic composite materials: PPS/C and PEEK/C. The total machining costs were computed for specific cases.

4

The influence of surface asymmetry of thermoplastic composites on their sound absorption

Gliścińska E., Michalak M., Krucińska I.

Composites Theory and Practice

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2014

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R. 14, nr 3

150--154

EN

Among sound insulating materials used in the automotive industry, multilayer systems consisting of foams, nonwovens, mats, knitted fabrics or porous panels in different combinations are very popular. These materials can be replaced by fibre reinforced composites. These composites can be good sound absorbing materials even at low thickness. One way to increase sound absorption is to form a composite with an optimal structure and surface topography. In this work, the investigations concern the sound absorption by thermoplastic composites with surface asymmetry. The influence of surface asymmetry of thermoplastic composites on their sound absorption coefficient was studied. The first kind of asymmetry concerns the structure of the composite surface, i.e. plastic and fibrous structure. The second kind of asymmetry concerns the topography of the composite surface, i.e. the one side of the composite surface is smooth and on the opposite side it is characterized by some relief. The sound absorption coefficient was measured for different sample orientations to the sound wave to assess the significance of the surface asymmetry and to indicate a more favourable composite side from the sound absorption point of view. Generally, both the surface structure asymmetry and surface topography asymmetry influence the sound wave behaviour and consequently increase the compositesound absorption.

PL

Spośród materiałów tłumiących dźwięk stosowanych w przemyśle samochodowym bardzo popularne są układy warstwowe składające się z pianek, włóknin, mat, dzianin lub porowatych paneli w różnych kombinacjach. Materiały takie mogą być zastąpione przez kompozyty wzmacniane włóknami, które mogą wykazywać dużą absorpcję dźwięku nawet przy małej ich grubości. Jednym ze sposobów zwiększenia absorpcji dźwięku jest zapewnienie optymalnej struktury i topografii kompozytu. W pracy przedstawiono badania dotyczące absorpcji dźwięku przez kompozyty charakteryzujące się asymetrią powierzchniową. Badano wpływ asymetrii powierzchniowej kompozytu na współczynnik absorpcji dźwięku. Pierwszy rodzaj asymetrii dotyczył struktury powierzchni kompozytu, tj. struktury włóknistej oznaczonej jako „fibrous”, i struktury bardziej sprasowanej, oznaczonej jako „plastic”. Drugi rodzaj asymetrii dotyczył topografii powierzchni kompozytu, tj. jedna strona kompozytu była gładka, druga posiadała specjalnie nadany relief. Współczynnik absorpcji dźwięku był wyznaczany dla różnego ukierunkowania próbki kompozytu w stosunku do padającej fali dźwiękowej, tak by można było ocenić znaczenie asymetrii powierzchniowej i wskazać bardziej korzystną stronę kompozytu z punktu widzenia możliwości tłumienia dźwięku. Generalnie, zarówno asymetria struktury, jak i topografii powierzchni kompozytu wpływa na zachowanie się tłumionej fali dźwiękowej, a w konsekwencji na wzrost absorpcji dźwięku przez kompozyt.

5

Kompozyty termoplastyczne dewulkanizatu terpolimeru etylenowo-propylenowo-dienowego z polipropylenem izotaktycznym

Parasiewicz W., Mężyński J., Niciński K., Ostaszewska U., Bieliński D.

Elastomery

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2011

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T. 15, nr 2

20-28

PL

W artykule przedstawiono technologię produkcji kompozytów termo-elastoplastycznych poprzez jednoczesną dewulkanizację odpadów gumowych i ich reaktywne mieszanie z polimerem termoplastycznym za pomocą współbieżnej wytłaczarki dwuślimakowej zaprojektowanej i wykonanej w Instytucie IMPIB. Na podstawie przeprowadzonych prób dokonano optymalizacji parametrów procesu. Otrzymano kompozyty termoplastyczne dewulkanizatu EPDM/PP o szerokim spektrum twardości, niewymagające wulkanizacji, kształtowane w procesie wytłaczania metodami stosowanymi w przetwórstwie tworzyw sztucznych. Kompozyty mogą być poddawane granulacji i powtórnie przetwarzane. Materiał może być stosowany do produkcji detali dla przemysłu motoryzacyjnego, nawierzchni sportowych, elementów antywibracyjnych, konfekcji drogowej, rur i węży nawadniających.

EN

The present paper is related to technology of production of thermo-elastic composites through simultaneously devulcanization of rubber wastes and their reactive mixing with thermoplastic polymer in co-rotating twin-screw extruder. The prototype of machinery was designed and made at Institute for Engineering of Polymer Materials & Dyes. On the basis of conducted tries the process was optimized. Thermoplastic composites of EPDM devulcanizate with PP were obtained in a wide spectra of hardness. These composites do not require vulcanization and can be processed with methods commonly used for plastics. The composites can be regranulated and reused. Such materials can be exploited in production of automotive parts, sport surfaces, antivibration systems, road confection, pipes or tubes.

6

Study the effect of commingling parameters on Glass / Polypropylene hybrid yarns properties

Mankodi H., Patel P

Autex Research Journal

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2009

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Vol. 9, no. 3

70--73

EN

The objective of this paper is to discuss effect of commingling parameter on characteristics of Glass/Polypropylene commingled hybrid yarns to get homogenous mix of matrix and reinforcement elements in the final yarn. A commingling machine developed to produce hybrid yarn using two techniques viz. mingling technique and hollow spindle wrapping technique using single machine is highlighted .The machine can run at speed upto 800 meters/min and for hybrid yarn it can go up to 200 meters/min. To study the effect of parameter three variable namely Air pressure, Overfeed and Take-up speed are take in to consideration and the Box-Behanken design is used for experimental setup. The hybrid yarn samples have been evaluated to investigate the influence of process variables the commingling characteristics of hybrid yarn viz. nip frequency; nip stability and nip regularity have also been studied. 'MINITAB' software is used for the analysis of test results. It was observed that effects of individual parameter as well as interaction effects are equally important in deciding final yarn quality. The structural analysis of hybrid yarn is done using SEM (Scanning electron microscope). To study the mixing behaviour of glass/polypropylene hybrid yarn three different methods have been used to prepare hybrid yarn viz. Friction spinning, hollow spindle wrapping, commingling. Its was clearly observed that commingled process gives better homogenous mixing of glass and polypropylene filaments compare to other two method. This yarn is used to make final laminate sample using hot press.

7

Kompozyty termoplastyczne z odpadami tekstylnymi

Kowalska E., Kijeńska M., Żubrowiska M.

Recykling

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2008

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nr 3

26-27

PL

Problem recyklingu odpadów tekstylnych stał się w ostatnich latach jednym z najczęściej podejmowanych tematów badań w czołowych zagranicznych ośrodkach naukowych, pracujących na rzecz włókiennictwa. Podjęte przez te placówki prace obejmują zagadnienia organizacyjne (logistyka zbiórki odpadów tekstylnych), recykling materiałowy z ukierunkowaniem na różne produkty utylizacji (np. kompozyty i laminaty).

8

On investigation of elasto-plastic stresses in thermoplastic composite beam under the transverse load by analytical method

Ozcan R., Aykul H.

Applied Mechanics and Engineering

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2000

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Vol. 5, no 3

543-555

EN

Elastic and elasto-plastic stress analysis is carried out in the thermoplastic composite beam under the transverse uniform load by using an analytical method. The expansion of elasto-plastic boundary is obtained by using the boundary conditions in the elasto-plastic region. the variations of the elasto-plastic region, the maximum normal and shear residual stresses are investigated according to the changes in the values of x coordinates.