Manufacturing and Testing of High Performance Sheet Moulding Compound

2008 ◽  
Vol 32 ◽  
pp. 141-144
Author(s):  
Meng Hou ◽  
Lin Ye
Keyword(s):  
High Performance ◽  
Mechanical Performance ◽  
Processing Conditions ◽  
Compression Moulding ◽  
Burst Test ◽  
Moulding Compound ◽  
Overall Performance ◽  
Tooling Design ◽  
Sheet Moulding Compound

The paper describes the manufacture of thin composite panels using high performance sheet moulding compound (SMC). Topics discussed within the paper include characterisation of curing and flow behaviour of SMC material, tooling design concept and determination of suitable processing conditions for compression moulding. A Full scale “Burst test” was carried out to evaluate the mechanical performance of SMC panels. The overall performance of the SMC panels was satisfactory with all panels failed beyond the specification value. The main failure mode was a through-thickness cracking. In addition, a geometrical non-linear numerical analysis was also carried out to investigate the stress distribution and deflection behaviour of SMC panel during “Burst testing”.

Experimental investigations and optimization of processibility of sheet moulding compound

2011 ◽  
Vol 31 (2-3) ◽  
Author(s):  
Bhaskara J.C. Babu ◽  
Sachin Waigaonkar ◽  
Amit Rajput
Keyword(s):  
Penetration Depth ◽  
Flow Behavior ◽  
Glass Fibers ◽  
Zinc Stearate ◽  
Experimental Investigations ◽  
Compression Moulding ◽  
Maturation Time ◽  
Moulding Process ◽  
Moulding Compound ◽  
Sheet Moulding Compound

Abstract Sheet moulding compound (SMC) is a combination of glass fibers and filled polyester resin. It is processed by a compression moulding process and finds extensive applications in structural, automotive, electrical and electronic industries. The compression moulding process is characterized by the flow behavior of SMC under heat and pressure in the press mould. This paper is focused on the prediction of ideal processibility conditions of SMC. The qualitative aspect of a properly thickened (matured) moulding compound could be seen from its tack-free nature, which was quantitatively calibrated in terms of penetration depth, measured by a specially constructed softness indicator. The weight (wt)% of calcium carbonate (CaCO3) as filler, magnesium oxide (MgO) as thickener, graphite (C) and zinc stearate [Zn (C18H35O2)2] (ZnSt) as lubricants along with the maturation time (Tm) were selected as process variables. Taguchi’s scheme of experimental design was adapted to perform the experiments. It was found that the higher levels of MgO and CaCO3 were favorable for a good penetration depth as well as a reduced maturation time. We have also found that a penetration depth of at least 5 mm was required for achieving good processability conditions of SMC. An optimization study was under taken to find the right blend of additives and fillers, at their minimal weights and in the least possible maturation time, to achieve the desired processability. This study is particularly useful in a production run to make moulded parts from SMC.

scholarly journals A Comprehensive Assessment of Commercial Process Simulation Software for Compression Moulding of Sheet Moulding Compound

2021 ◽  
Author(s):  
Connie Cheng Qian ◽  
Abhaye Deshpande ◽  
Mona Jesri ◽  
Richard Groves ◽  
Neil Reynolds ◽  
...  
Keyword(s):  
Experimental Data ◽  
Process Simulation ◽  
Simulation Software ◽  
Comprehensive Assessment ◽  
Design Tool ◽  
Compression Moulding ◽  
Constitutive Material Model ◽  
Injection Moulding Process ◽  
Moulding Compound ◽  
Sheet Moulding Compound

With a growing interest in the application of carbon fibre Sheet Moulding Compound (SMC), a number of commercial software packages have been developed for the simulation of compression moulding of SMC. While these packages adopt different algorithms and meshing strategies, the constitutive material model and processing control are usually adapted from injection moulding process simulation. Little has been done in the literature for assessing the capabilities of these software as design tools, and more importantly, validating the process simulation results using experimental data. This paper aims to provide an independent and comprehensive assessment of existing well-known process simulation software for SMC compression moulding. The selected software will be compared in terms of material models, and available processing settings in order to determine their robustness as a compression moulding design tool. The predictive accuracy of the software will also be assessed by comparing the compression force and filling patterns against the experimental data.

Determination of melt processing conditions for high performance amorphous thermoplastics for large format additive manufacturing

2018 ◽  
Vol 21 ◽  
pp. 125-132 ◽  
Author(s):  
Christine Ajinjeru ◽  
Vidya Kishore ◽  
Peng Liu ◽  
John Lindahl ◽  
Ahmed Arabi Hassen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Melt Processing ◽  
Processing Conditions ◽  
Large Format

scholarly journals Combination of Carbon Fibre Sheet Moulding Compound and Prepreg Compression Moulding in Aerospace Industry

2014 ◽  
Vol 81 ◽  
pp. 1601-1607 ◽  
Author(s):  
Jens Wulfsberg ◽  
Axel Herrmann ◽  
Gerhard Ziegmann ◽  
Georg Lonsdorfer ◽  
Nicole Stöß ◽  
...  
Keyword(s):  
Carbon Fibre ◽  
Aerospace Industry ◽  
Compression Moulding ◽  
Moulding Compound ◽  
Sheet Moulding Compound

Effects of Fuel Thickness on Thermo-Mechanical Performance of U10Mo Monolithic Fuel Plates

2017 ◽  
Author(s):  
Hakan Ozaltun ◽  
Barry H. Rabin
Keyword(s):  
High Performance ◽  
Mechanical Performance ◽  
Behavioral Model ◽  
High Density ◽  
Foil Thickness ◽  
Operational Parameters ◽  
Operational Variables ◽  
Sensitivity Studies ◽  
Overall Performance ◽  
Performance Research

Monolithic fuels are being considered for conversion of high performance research and test reactors. These plate-type fuels are comprised of a low enrichment, high density U-Mo alloy fuels within an aluminum cladding. Although the plates have demonstrated satisfactory performance; still, use of a high density fuel in a foil form retains technical challenges that could affect the overall performance. To understand performance of this new design during fabrication and irradiation, the plates have been evaluated for various geometrical and operational variables. As a part of these set of parametric sensitivity studies, effects of foil thickness on performance were studied. Because high performance research reactors will utilize different fuel thicknesses, it is necessary to evaluate possible effects for a range of thicknesses that are being considered for various designs. Based on the preliminary design specifications, the fuel thicknesses were varied between the limiting cases. The bounding fuel thicknesses were 0.203 mm as minimum that is projected for ATR, and 0.635 mm as maximum that is projected for MITR. To study possible effects, a behavioral model was developed for a selected plate from RERTR-12 experiments and the plate was simulated with as run irradiation history. The simulations were repeated for a range of fuel thicknesses, while keeping the cladding thickness and the operational parameters the same. The results have indicated that the plates with thicker fuels would have higher temperatures, deformations and shutdown stresses. To investigate the effects of fuel thickness exclusively, operational parameters were scaled. In particular, a second set of simulations with prorated volumetric heat generation rates were performed. The results indicated that the fabrication stresses in the fuel foil decrease with an increasing fuel thickness. On contrary, irradiation stresses of the fuel at shutdown are higher for the plates with thicker fuels. Greater peak deformations occurred in plates with thicker fuels.

scholarly journals Novel Reactive Flex Configuration in Kiwi Wing Foil Surfboard

2021 ◽  
Vol 6 (1) ◽  
pp. 6
Author(s):  
Adrien M. Fat Cheung ◽  
Klaudio Bari
Keyword(s):  
Carbon Fibre ◽  
High Performance ◽  
Large Deflection ◽  
Mechanical Performance ◽  
Ocean Waves ◽  
Core Material ◽  
Flexural Stress ◽  
Compression Moulding ◽  
Element Analysis ◽  
Fea Simulation

The creation of an ideal surfboard is art. The design and construction depend on the individual surfer’s skill level and type of the required performance. In this research, four fuselage concepts were carefully explored to meet the following unique needs: lightweight, strong, and a fast-manufacturing process. The fuselages were manufactured by compression moulding using skin and core materials. The skin material was selected to be unidirectional (UD) carbon fibre, discontinuous carbon fibre (SMC) and Filava quadriaxial fibre impregnated with epoxy, while the core material was selected to be lightweight PVC foam. To assess the mechanical performance, three-point bending has been performed according to BS-ISO 14125 and validated using Finite Element Analysis (FEA) using Ansys software. As expected, the flexural test revealed that the UD carbon fibre fuselage was the strongest and SMC was the weakest, while large deflection was seen in Filava fibre fuselages before failure, showing great reactive flex that promotes projection during surfing. The experimental results show good agreement with FEA simulation, and the locations of the physical failure in the fuselage matches the location of maximum flexural stress obtained from FEA simulation. Although all fuselages were found to carry a surfer weight of 150 kg, including a factor of safety 3, except the SMC fuselage, due to shrinkage. The Filava fibre fuselages were seen to have a large deflection before failure, showing great flexibility to handle high ocean waves. This promotes the potential use of reactive flex in high performance sports equipment, such as surfing boards. A large shrinkage must be taken under consideration during compression moulding that depends on fibre orientation, resin nature, and part geometry.

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