Experimental investigation of the curing behaviour of fibre composite structures with snap-cure polymer systems

2018 ◽  
Vol 9 (6) ◽  
pp. 768-778
Author(s):  
Rafal Stanik ◽  
Albert Langkamp ◽  
Michael Müller ◽  
Maik Gude ◽  
Anna Boczkowska
Keyword(s):  
Experimental Investigation ◽  
Temperature Field ◽  
Process Parameters ◽  
Material Properties ◽  
Manufacturing Process ◽  
Composite Structures ◽  
Fibre Composite ◽  
Uniform Design ◽  
Curing Process ◽  
Content Type

PurposeNovel snap-cure polymers (SCPs), as matrix systems for high-performance fibre composite materials, provide high potential for manufacturing of component families with small batch sizes and high variability. Especially, the processing of powdered SCP is associated with relatively simple and inexpensive tools. In addition, because of their curing behaviour, they allow short tooling times so that the production of small batch size components is possible in relatively short cycle times. To enable an efficient manufacturing process, an understanding of the curing process is necessary. An adjustment of the process parameters for a uniform design of the temperature field in the material during the manufacturing process is essential. The paper aims to discuss this issue.Design/methodology/approachFor this, a powder SCP resin system was investigated under process-specific conditions. An experimental test approach for determination of various thermal and kinetic material properties was developed. For the adjustment of the process parameters and monitoring of the curing state during the manufacturing process, a kinetic material model was determined. In the end, the validation of the determined model was performed. For this, the temperature distribution under process- specific conditions was measured in order to monitor the curing state of the material.FindingsThe experimental investigation showed an uneven temperature field in the material, which leads to an inhomogeneous curing process. This can lead to residual stresses in the structure, which have a critical impact on the material properties.Originality/valueThe determined kinetic model allows a prediction of the curing reaction and adjustment of the process parameters which is essential, especially for thick-walled components with SCPs.

Role of process parameters during additive manufacturing by direct metal deposition of Inconel 718

2017 ◽  
Vol 23 (5) ◽  
pp. 919-929 ◽  
Author(s):  
Bo Chen ◽  
Jyoti Mazumder
Keyword(s):  
Additive Manufacturing ◽  
Cooling Rate ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Processing Parameters ◽  
Forming Quality ◽  
Content Type ◽  
Forming Characteristics ◽  
The Relationship

Purpose The aim of this research is to study the influence of laser additive manufacturing process parameters on the deposit formation characteristics of Inconel 718 superalloy, the main parameters that influence the forming characteristics, the cooling rate and the microstructure were studied. Design/methodology/approach Orthogonal experiment design method was used to obtain different deposit shape and microstructure using different process parameters by multiple layers deposition. The relationship between the processing parameters and the geometry of the cladding was analyzed, and the dominant parameters that influenced the cladding width and height were identified. The cooling rates of different forming conditions were obtained by the secondary dendrite arm spacing (SDAS). Findings The microstructure showed different characteristics at different parts of the deposit. Cooling rate of different samples were obtained and compared by using the SDAS, and the influence of the process parameters to the cooling rate was analyzed. Finally, micro-hardness tests were done, and the results were found to be in accordance with the micro-structure distribution. Originality/value Relationships between processing parameters and the forming characteristics and the cooling rates were obtained. The results obtained in this paper will help to understand the relationship between the process parameters and the forming quality of the additive manufacturing process, so as to obtain the desired forming quality by appropriate parameters.

Assessment of mechanical properties and flammability of magnesium oxide/PA12 composite material for SLS process

2019 ◽  
Vol 25 (1) ◽  
pp. 176-186 ◽  
Author(s):  
Sunil Kumar Tiwari ◽  
Sarang Pande ◽  
Santosh M. Bobade ◽  
Santosh Kumar
Keyword(s):  
Composite Material ◽  
Composite Materials ◽  
Magnesium Oxide ◽  
Process Parameters ◽  
Material Properties ◽  
Composite Powder ◽  
Flow Index ◽  
Oxide Material ◽  
Content Type ◽  
Material Development

Purpose The purpose of this paper is to propose and develop PA2200-based composite powder containing 0-15 Wt.% magnesium oxide before directly using it in selective laser sintering (SLS) machine to produce end-use products for low-volume production in the engineering applications with keen focus to meet the functional requirements which rely on material properties. Design/methodology/approach The methodology reported emphasises PA2200-based composite powder containing 0-15 Wt.% magnesium oxide development for SLS process which starts with preparation and characterisation of composite material, thermal and rheological study of composite material to decide optimum process parameters for SLS process machine to get optimal part properties. Further, to verify composite material properties, a conventional casting methodology is used. The composition of composite materials those possessing good properties are further selected for processing in SLS process under optimal processing parameters. Findings The process parameters of SLS machine are material-dependent. The effect of temperature in X-ray diffraction profile is negligible in the case of magnesium oxide reinforced PA2200 composite material. The cyclic heating of material increases melting point temperature, this grounds to modify part bed temperature of material every time before processing on SLS machine to uphold build part properties, as well as material. With the rise in temperature, the Melt flow index and rheological property of materials change. The magnesium oxide reinforced PA2200 composite material has high thermal stability than pure PA2200 material. By the addition of small quantity of magnesium oxide, most of the mechanical property and flammability property improves while elongation at break (percentage) decreases significantly. Practical implications The proposed PA2200-based composite powder containing 0-15 Wt.% magnesium oxide material development system and casting metrology to verify developed material properties will be very useful to develop new composite material for SLS process with use of less material. The developed methodology has proven, especially in the case where non-experts or student need to develop composite material for SLS process according to the property requirement of applications. Originality/value Unlike earlier composite material development methodology, the projected methodology of polymer-based composite material and confirmation of material properties instead of commencing SLS process provides straight forward means for SLS process composite materials development with less use of the material and period of time.

Three-dimensional numerical study of heat-affected zone in induction welding of tubes

2020 ◽  
Vol 39 (1) ◽  
pp. 213-219
Author(s):  
Prerana Das ◽  
John Inge Asperheim ◽  
Bjørnar Grande ◽  
Thomas Petzold ◽  
Dietmar Hömberg
Keyword(s):  
Process Parameters ◽  
Material Properties ◽  
High Frequency ◽  
3D Model ◽  
Welding Process ◽  
Induction Coil ◽  
Content Type ◽  
Non Linear ◽  
Tube Welding ◽  
Welding Line

Purpose Quality of the weld joint produced by high-frequency induction (HFI) welding of steel tubes is attributed to a number of process parameters. There are several important process parameters such as the speed of the welding line, the angle of the approaching strip edges, the physical configuration of the induction coil, impeder, formed steel strip and weld rolls with respect to each other, the pressure of the weld rolls and frequency of the high-frequency current in the induction coil. The purpose of this paper is to develop a 3D model of tube welding process that incorporates realistic material properties and movement of the strip. Design/methodology/approach 3D numerical simulation by the finite element method (FEM) can be used to understand the influence of these process parameters. In this study, the authors have developed a quasi-steady model along with the coupling of electromagnetic and thermal model and incorporation of non-linear electromagnetic and thermal material properties. Findings In this study, 3D FEM model has been established which gives results in accordance with previously published work on induction tube welding. The effect of the Vee-angle and frequency on the temperature profile created in the strip edge during the electromagnetic heating is studied. Practical implications The authors are now able to simulate the induction tube welding process at a more reasonable computational cost enabling an analysis of the process. Originality/value A 3D model has been developed for induction tube welding. A non-linearly coupled system of Maxwell’s electromagnetic equation and the heat equation is implemented using the fixed point iteration method. The model also takes into account non-linear magnetic and thermal material properties. Adaptive remeshing is implemented to optimise mesh size for the electrical skin depth of induced current in the strip. The model also accounts for the high welding-line speeds which influence the mode of heat transfer in the strip.

Numerical investigation of temperature field of different mechanisms in laser forming

2011 ◽  
Vol 226 (8) ◽  
pp. 2118-2125 ◽  
Author(s):  
Yongjun Shi ◽  
Peng Yi ◽  
Yancong Liu
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Process Parameters ◽  
Material Properties ◽  
Industrial Applications ◽  
Laser Forming ◽  
Temperature Zone ◽  
Numerical Investigations ◽  
Distribution Features ◽  
Plate Size

In laser forming, deformation of a plate is different when different mechanisms play dominant roles. A deformation field depends on a temperature field that is related to process parameters, material properties and plate size. Numerical investigations of temperature distribution with different process parameters were carried out when different mechanisms were active. A critical temperature for generating plastic deformation was investigated. Four temperature feature parameters were defined based on the temperature distribution characteristics of the high-temperature zone. The numerical results show that the temperature gradient is obviously different under different mechanism conditions. The temperature distribution features for the different mechanisms have a larger difference, which is helpful for the discrimination of different mechanisms according to the temperature field in real industrial applications.

Application of Six Sigma methodology in an Indian chemical company

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Vishal Singh Patyal ◽  
Sachin Modgil ◽  
Maddulety Koilakuntla
Keyword(s):  
Process Parameters ◽  
Six Sigma ◽  
Manufacturing Process ◽  
System Analysis ◽  
Phase Measurement ◽  
Content Type ◽  
Customer Complaints ◽  
Chemical Company ◽  
Shift Type ◽  
Data Driven Approach

PurposeThe aim of this paper is to deploy Six Sigma (SS) methodology for addressing the customer complaints pertaining to Chemical-X in an Indian chemical company.Design/methodology/approachThe study followed a structured Define, Measure, Analyze, Improve, Control (DMAIC) approach to address the customer complaints. The complaints have been classified into different categories along with a project charter in the define phase. In the measure phase, measurement system analysis (MSA) and supplier, input, process, output and control (SIPOC) have been applied. In the analyze and improve phase, why–why analysis, process capability study, how–how analysis, Gage repeatability and reproducibility and Taguchi design have been applied to optimize the manufacturing process parameters for Chemical-X. Lastly, in the control phase, validation of 20 batches has been piloted to validate the optimized parameters.FindingsThe findings of this study highlight the optimization and prioritization of the process parameters. It shows that humidity has the least impact on the manufacturing of Chemical-X, whereas shift type has the maximum impact. The experimental output indicates that the 1st Shift, the holding time after grinding should be twenty-four hours, and the temperature after grinding should be 40 °C to reduce the customer complaints concerning lumps formation in Chemical-X.Research limitations/implicationsThe study is performed for a single product (Chemical-X). It has focused only from the manufacturing process view and not from the transportation, suppliers and downstream supply chain view.Originality/valueA systematic and data-driven approach of the SS methodology ensured that the customer complaints due to lumps formation reduced from 5% (approx.) to 1% (approx.) which resulted in the cost saving of INR 4 million (approx.) annually.

Optimization of surface quality and machining time in micro-milling of glass

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ali Dinc ◽  
Ali Mamedov
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Material Properties ◽  
Feed Rate ◽  
Cutting Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Time ◽  
Content Type ◽  
Glass Material

Purpose Glass is a brittle material produced from silica, which has fine material properties, Owing to its sophisticated material properties, glass has found wide application in various high-technological fields such as aviation, aerospace, communication, optics, biomedical and electronics. However, glass is known as difficult to machine material because of its tendency to brittle fracture during machining. This paper aims to investigate the effects of cutting parameters on surface quality and machining time during micro-milling of brittle glass components. Design/methodology/approach A comprehensive genetic algorithm-based optimization strategy is used for selection of process parameters such as cutting speed, feed rate and depth of cut. Effectiveness of the proposed strategy is validated by conducting micro-milling cutting experiments on soda-lime glass material. Findings Results showed that the generated surface quality drastically decrease with increase in the amount of removed material. Lower depth of cut and feed rate result in less amount of cracks formed on machined surface. Also, it is observed that the increase in cutting speed results in better surface quality. Having desired surface quality in shorter machining time directly reduces energy consumed during manufacturing, which is reducing environmental impact of glass parts. Originality/value The novelty of this research work lies in simultaneously considering the effects of cutting speed, feed rate, depth of cut on surface quality and machining time for micro-milling operation of brittle glass material. The model is able to find optimum process parameters for high surface quality and minimum machining time.

A model of bead size based on the dynamic response of CMT-based wire and arc additive manufacturing process parameters

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Xuewei Fang ◽  
Chuanqi Ren ◽  
Lijuan Zhang ◽  
Changxing Wang ◽  
Ke Huang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Dynamic Response ◽  
Prediction Model ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Critical Issue ◽  
Cold Metal Transfer ◽  
Bead Width ◽  
Content Type ◽  
Bead Size

Purpose This paper aims at fabricating large metallic components with high deposition rates, low equipment costs through wire and wire and arc additive manufacturing (WAAM) method, in order to achieve the morphology and mechanical properties of manufacturing process, a bead morphology prediction model with high precision for ideal deposition of every pass was established. Design/methodology/approach The dynamic response of the process parameters on the bead width and bead height of cold metal transfer (CMT)-based AM was analyzed. A laser profile scanner was used to continuously capture the morphology variation. A prediction model of the deposition bead morphology was established using response surface optimization. Moreover, the validity of the model was examined using 15 groups of quadratic regression analyzes. Findings The relative errors of the predicted bead width and height were all less than 5% compared with the experimental measurements. The model was then preliminarily used with necessary modifications, such as further considering the interlayer process parameters, to guide the fabrication of complex three-dimensional components. Originality/value The morphology prediction of WAAMed bead is a critical issue. Most research has focused on the formability and defects in CMT-based WAAM and little research on the effect of process parameters on the morphology of the deposited layer in CMT-based WAAM has been conducted. To test the sensitivities of the processing parameters to bead size, the dynamic response of key parameters was investigated. A regression model was established to guide the process parameter optimization for subsequent multi-layer or component deposition.

Application Of Cusum Chart In Control Of Paper Quality

GIS Business ◽  
2020 ◽  
Vol 14 (6) ◽  
pp. 1062-1069
Author(s):  
S.Ramesh ◽  
B.A.Vasu
Keyword(s):  
Process Parameters ◽  
Manufacturing Process ◽  
Paper Industry ◽  
Primary Data ◽  
Cusum Chart ◽  
Paper Machine ◽  
Statistical Control ◽  
Operating Characteristics ◽  
Small Shift

This paper is an attempt to assess if the manufacturing process of paper machine is in statistical control thereby improving the quality of paper being produced in a paper industry at the time of process itself. Quality is the foremost criteria for achieving the business target. Therefore, emphasis was made on controlling the quality of paper at the time of manufacturing process itself, rather than checking the finished lots at a later time.  This control on quality will help the industry deduct the small shift in the process parameters and modify the operating characteristics at the time of production itself rather than receiving complaints from customers at a later stage.  This paper describes controlling quality at the time of manufacture itself and helps the industry to concentrate on quality at low cost. The researcher has collected primary data at a leading paper industry during October, 2019.  Though X-bar and Range charges were primarily used, CUSUM charts were used to sense the minor shifts in manufacturing process, to explore the possibility of adjusting process parameters during manufacture of paper.

scholarly journals Research on the Manufacturing Quality of Co-Cured Hat-Stiffened Composite Structure

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 2747
Author(s):  
Xiangwen Ju ◽  
Jun Xiao ◽  
Dongli Wang ◽  
Cong Zhao ◽  
Xianfeng Wang
Keyword(s):  
Composite Structures ◽  
Sound Pressure ◽  
Integration Method ◽  
Complex Geometry ◽  
Sound Field ◽  
Thickness Measurement ◽  
Curing Process ◽  
The Finite Element Method ◽  
Manufacturing Quality

The stringer-stiffened structure is widely used due to its excellent mechanical properties. Improving the manufacturing quality of stringer-stiffened structure which have complex geometry is important to ensure the bearing capacity of aviation components. Herein, composite hat-stiffened composite structures were manufactured by different filling forms and bladders with various properties, the deformation of silicone rubber bladder in co-curing process was studied by using the finite element method. The thickness measurement at different positions of the hat-stiffened structure was performed to determine the best filling form and bladder property. Moreover, in view of the detection difficulties in R-zone of stringer, numerical simulation was performed to get the sound pressure and impulse response of at the R-zone of stringer by Rayleigh integration method, and an effective equipment which could stably detect the manufacturing quality of R-zone was designed to verify the correctness of sound field simulation and realize the detection of stringer. With the optimum filling form and bladder properties, hat-stiffened composites can be manufactured integrally with improved surface quality and geometric accuracy, based on co-curing process.

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