Analysis of Additive Alignment in a 90∘ Elbow Channel

2020 ◽  
Vol 28 (04) ◽  
pp. 2050032
Author(s):  
Hoang Minh Khoa Nguyen ◽  
Dong-Wook Oh
Keyword(s):  
Flow Visualization ◽  
Fiber Type ◽  
Weight Ratio ◽  
High Strength ◽  
Short Fiber ◽  
Industrial Applications ◽  
Injection Molding Process ◽  
Molding Process ◽  
Corner Region ◽  
Liquid Polymer

Short-fiber reinforced polymer composites have been widely used in industrial applications due to high strength-to-weight ratio, versatile manufacturing process, and etc. The alignment of fiber type additives plays an important role in the mechanical properties of a composite material. In this paper, an injection molding process was imitated with a liquid polymer composite flow inside a [Formula: see text] elbow channel. We performed a flow visualization experiment and analyzed the additive alignment of carbon fiber flowing in the polydimethylsiloxane (PDMS) medium. By analyzing the flow visualization images, the angle changes at the corner region of the elbow channel were calculated. At the corner region, the change of passage direction leads to the change of fiber orientation. It was observed that near to the convex region, fibers have angle change values larger than the fibers traveling near to the concave region.

Sintering metal injection molding parts of tungsten-based steel using microwave and conventional heating methods

2018 ◽  
Vol 233 (11) ◽  
pp. 2138-2146 ◽  
Author(s):  
Veeresh Nayak C ◽  
Ramesh MR ◽  
Vijay Desai ◽  
Sudip Kumar Samanta
Keyword(s):  
Injection Molding ◽  
Microwave Sintering ◽  
Weight Ratio ◽  
High Strength ◽  
Conventional Heating ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Homogeneous Microstructure ◽  
Microwave Assisted

In recent years, the near net shape metal injection molding process combines desirable features of plastic injection molding and powder metallurgy processes to gain high strength-to-weight ratio for manufacturing complex-shaped parts. The metal injection molding process consists of mixing, molding, debinding, and sintering. Microwave processing has attracted much attention in global research because of its unique features such as its ability to heat and sinter a wide variety of metals and its significant advantages in energy efficiency, processing speed, and compatibility. Also, it presents few environmental risks and can produce refined microstructures. The injected samples to be sintered are composed of fine tool steel metal powder and binders, stearic acid, paraffin wax, low-density polyethylene, and polyethylene glycol (600). In recent years, microwave-assisted post-treatment is considered a novel method for processing green parts. In this work, the green parts are subjected to high-intensity microwave fields which operate at a frequency of 2.45 GHz. Metal injection molding compacts were sintered using multi-mode microwave radiation. The sintering of a metal injection molding compact by microwaves has hardly been reported. The metal injection molding compact showed better results than those produced by sintering with conventional heating. This study evaluates the effect of conventional sintering and microwave sintering on mechanical properties. By optimizing the sintering process, increased sintered hardness, a more homogeneous microstructure, and greater shrinkage were obtained using microwave-assisted sintering.

Efficient Multiscale Methods for Viscoelasticity and Fatigue of Short Fiber-Reinforced Polymers

2019 ◽  
Vol 809 ◽  
pp. 473-479
Author(s):  
Fabian Welschinger ◽  
Jonathan Köbler ◽  
Heiko Andrä ◽  
Ralf Müller ◽  
Matti Schneider ◽  
...  
Keyword(s):  
Fatigue Behavior ◽  
Short Fiber ◽  
Industrial Applications ◽  
Multiscale Methods ◽  
Fiber Reinforced Polymers ◽  
Fast Fourier Transformation ◽  
Injection Molding Process ◽  
Fiber Reinforced ◽  
Molding Process ◽  
Numerical Effort

To predict the nonlinear mechanical behavior of components made of short fiber-reinforced plastics (SFRP) under long term and cyclic loading, coupled process and component simulations are required. The injection molding process leads to locally varying fiber orientations within the component. This varying microstructure [1] significantly influences the viscoelastic and fatigue behavior. The interaction between the microstructure [2] and the nonlinear macroscopic properties is resolved by a coupled fast Fourier transformation and finite element two-scale method (FFT-FEM), where the fiber orientation tensor is obtained by analyzing μCT images or by the corresponding process simulation. The aim of this work is to reduce the numerical costs of such a multiscale method. In a first step, the highly efficient micro-scale solver FeelMath [3,4] using an FFT-based preconditioner is presented. Afterwards, a numerical scheme based on a precomputed database trained with FeelMath simulations on the microscale and a model order reduction algorithm, is discussed. The combination of these ideas reduces the numerical effort, such that the method is applicable for industrial problems. Comparative studies of the fully coupled and reduced model document the high accuracy of this approach. The overall performance of this methodology is demonstrated by three-dimensional, industrial applications.

scholarly journals Sequential Laser–Mechanical Drilling of Thick Carbon Fibre Reinforced Polymer Composites (CFRP) for Industrial Applications

Polymers ◽  
2021 ◽  
Vol 13 (13) ◽  
pp. 2136
Author(s):  
Sharizal Ahmad Sobri ◽  
Robert Heinemann ◽  
David Whitehead
Keyword(s):  
Carbon Fibre ◽  
Polymer Composites ◽  
Weight Ratio ◽  
High Strength ◽  
Industrial Applications ◽  
Fibre Laser ◽  
Reinforced Polymer ◽  
Carbon Fibre Reinforced Polymer ◽  
Fibre Reinforced Polymer ◽  
Thrust And Torque

Carbon fibre reinforced polymer composites (CFRPs) can be costly to manufacture, but they are typically used anywhere a high strength-to-weight ratio and a high steadiness (rigidity) are needed in many industrial applications, particularly in aerospace. Drilling composites with a laser tends to be a feasible method since one of the composite phases is often in the form of a polymer, and polymers in general have a very high absorption coefficient for infrared radiation. The feasibility of sequential laser–mechanical drilling for a thick CFRP is discussed in this article. A 1 kW fibre laser was chosen as a pre-drilling instrument (or initial stage), and mechanical drilling was the final step. The sequential drilling method dropped the overall thrust and torque by an average of 61%, which greatly increased the productivity and reduced the mechanical stress on the cutting tool while also increasing the lifespan of the bit. The sequential drilling (i.e., laser 8 mm and mechanical 8 mm) for both drill bits (i.e., 2- and 3-flute uncoated tungsten carbide) and the laser pre-drilling techniques has demonstrated the highest delamination factor (SFDSR) ratios. A new laser–mechanical sequence drilling technique is thus established, assessed, and tested when thick CFRP composites are drilled.

SYNTHESIS AND CHARACTERISATION OF WOVENROVING GLASS MAT FOR EPOXYCOMPOSITES

2020 ◽  
Vol 15 (4) ◽  
Author(s):  
Mahesh Mallampati ◽  
Sreekanth Mandalapu ◽  
Govidarajulu C
Keyword(s):  
Tensile Strength ◽  
Glass Fiber ◽  
Low Cost ◽  
Weight Ratio ◽  
High Strength ◽  
Hardness Test ◽  
Industrial Applications ◽  
Sem Analysis ◽  
Low Thermal Expansion ◽  
Manufacturing Techniques

The composite materials are replacing the traditional materials because oftheir superior properties such as high tensile strength, low thermal expansion, high strength to weight ratio, low cost, lightweight, high specific modulus, renewability and biodegradability which are the most basic & common attractive features of composites that make them useful for industrial applications. The developments of new materials are on the anvil and are growing day by day. The efforts to produce economically attractive composite components have resulted in several innovative manufacturing techniques currently being used in the composites industry. Generally, composites consist of mainly two phases i.e., matrix and fiber. In this study, woven roving mats (E-glass fiber orientation (-45°/45°,0°/90°, - 45°/45°),UD450GSM)were cut in measured dimensions and a mixture of Epoxy Resin (EPOFINE-556, Density-1.15gm/cm3), Hardener (FINE HARDTM 951, Density- 0.94 gm/cm3) and Acetone [(CH3)2CO, M= 38.08 g/mol] was used to manufacture the glass fiber reinforced epoxy composite by hand lay-up method. Mechanical properties such as tensile strength, SEM analysis, hardness test, density tests are evaluated.

Prediction of Elastic Modulus of Glass Short Fiber/Wood Powder/Polypropylene Hybrid Composites

2013 ◽  
Author(s):  
Ying Yu ◽  
Manabu Nomura ◽  
Hiroyuki Hamada
Keyword(s):  
Mechanical Properties ◽  
Elastic Modulus ◽  
Hybrid Composites ◽  
Length Distribution ◽  
Wood Particle ◽  
Short Fiber ◽  
Injection Molding Process ◽  
Orientation Factor ◽  
Wood Powder ◽  
Molding Process

Recent years, thermoplastics incorporated with particulate fillers have been gained high interests. To improve the mechanical properties of the natural particle reinforced polymer plastics, hybrid structure has been applied on the composite combining natural particle with stronger synthetic fibers. However, the reinforcing mechanism of the hybrid composite is quite complicated. Experiments on it may become time consuming and cost prohibitive. Therefore, researchers are interested in studying variable models to predict the elastic properties of the composites. In this study, glass short fiber/wood particle/pp hybrid composites were prepared by injection molding process at a fixed reinforcement to matrix ratio of 51:49. 4 kinds of hybrid specimens with glass fiber/wood particle ratios of 41:10, 31:20, 21:30 and 11:40 were fabricated. The effect of hybridization content on the mechanical properties of the composites was evaluated based on tensile test. Theoretically, the elastic modulus of hybrid composites was predicted by using the rule of hybrid mixtures (RoHM) equation and classical lamination theory (CLT) and the accuracy of the two estimation models has been discussed. Results showed that it can be considered the hybridization of wood powder into glass/PP composite could contribute to a similar high elastic modulus with high green degree. On the other hand, the fiber orientation factor, fiber length distribution factor, powder dispersion factor were very important factors and need to be considered in the prediction model.

Impact of the Harsh Environment on E-Glass Epoxy Composite

2019 ◽  
Author(s):  
Amir Hussain Idrisi ◽  
Abdel-Hamid Ismail Mourad ◽  
Beckry Abdel-Magid ◽  
Mohammad Mozumder ◽  
Yaser Afifi
Keyword(s):  
High Temperature ◽  
Composite Materials ◽  
Oil And Gas ◽  
Epoxy Composite ◽  
Uv Light ◽  
Weight Ratio ◽  
High Strength ◽  
Industrial Applications ◽  
Harsh Environment ◽  
Sustained Loads

Abstract Composite materials are being used in many industrial applications such as automobile, aerospace, marine, oil and gas industries due to their high strength to weight ratio. The long-term effect of sustained loads and environmental factors that include exposure to UV light, temperature, and moisture have been under investigation by many researchers. The major objective of this study is to evaluate the effects of harsh environment (e.g. seawater and high temperature) on the structural properties of E-glass epoxy composite materials. These effects were studied in terms of seawater absorption, permeation of salt and contaminants, chemical and physical bonds at the interface and degradation in mechanical properties. Samples were immersed in seawater at room temperature (23°C), 65°C and 90°C for the duration of 6 months. Results show that seawater absorption increased with immersion time at 23°C and 65°C, whereas the weight of the specimens decreased at 90°C. The moisture causes swelling at 23°C and 65°C and breakdown of chemical bonds between fiber and matrix at 90°C. It is observed that high temperature accelerates the degradation of the E-glass epoxy composite. At 90°C, the tensile strength of E-glass epoxy sharply decreased by 72.92% but no significant change was observed in modulus of elasticity of the composite.

scholarly journals Numerical Modelling and Analytical Comparison of Delamination during Cryogenic Drilling of CFRP

Polymers ◽  
2021 ◽  
Vol 13 (22) ◽  
pp. 3995
Author(s):  
Arunachalam S. S. Balan ◽  
Chidambaram Kannan ◽  
Kunj Jain ◽  
Sohini Chakraborty ◽  
Siddharth Joshi ◽  
...  
Keyword(s):  
Numerical Models ◽  
Weight Ratio ◽  
High Strength ◽  
Industrial Applications ◽  
Reinforced Polymers ◽  
Carbon Fibre Reinforced Polymers ◽  
Subsequent Effect ◽  
Drilling Conditions ◽  
Machining Operations ◽  
Innovative Techniques

Carbon-Fibre-Reinforced Polymers (CFRPs) have seen a steady rise in modern industrial applications due to their high strength-to-weight ratio and corrosion resistance. However, their potential is being hindered by delamination which is induced on them during machining operations. This has led to the adoption of new and innovative techniques like cryogenic-assisted machining which could potentially help reduce delamination. This study is aimed at investigating the effect of cryogenic conditions on achieving better hole quality with reduced delamination. In this paper, the numerical analysis of the drilling of CFRP composites is presented. Drilling tests were performed experimentally for validation purposes. The effects of cooling conditions and their subsequent effect on the thrust force and delamination were evaluated using ABAQUS/CAE. The numerical models and experimental results both demonstrated a significant reduction in the delamination factor in CFRP under cryogenic drilling conditions.

scholarly journals Correlation between the Microstructure and Mechanical Properties of W-Bearing Ti-6Al-4V Alloys

2021 ◽  
Vol 59 (6) ◽  
pp. 357-364
Author(s):  
Godwin Kwame Ahiale ◽  
In-Seok Kye ◽  
Young Sam Kwon ◽  
Yong-Jun Oh
Keyword(s):  
Mechanical Properties ◽  
High Strength ◽  
Solid Solution Hardening ◽  
Powder Injection ◽  
Injection Molding Process ◽  
Molding Process ◽  
Β Phase ◽  
Α Phase ◽  
The Matrix ◽  
Indentation Tests

W-containing Ti-6Al-4V alloys (W=0, 1, and 5 wt%) were fabricated by the powder injection molding process, and the corresponding effects of tungsten content on the mechanical properties and microstructure of the alloys were investigated. The alloy powders were sintered at 1200 °C and then hot-isostatically-pressed at 900 °C. The fabricated alloys were subjected to microstructural and chemical analyses, and tensile and nano-indentation tests. The yield strength and tensile strength proportionally increased as the W content was increased from 0 wt% to 5 wt%. Ductility was not affected by the addition of up to 5 wt% W due to its complete dissolution in the matrix. Higher W addition induced finer α/β lamellar microstructures and increased the β to α phase ratio. Moreover, the added W dissolved preferentially in the β phase by solid solution hardening, increasing the hardness of the β phase, which originally was significantly softer than the α phase. For the alloys containing up to 5 wt% W, the strengthening without ductility loss was attributed to the finer α/β lamellae and the volume increase in the β phase hardened by W. These results suggest that adding W to Ti-6Al-4V alloy is a promising method for developing Ti alloys with both high strength and toughness.

scholarly journals Physicomechanical behavior of composites of polypropylene, and mineral fillers with different process cycles

DYNA ◽  
2018 ◽  
Vol 85 (207) ◽  
pp. 260-268 ◽  
Author(s):  
Carolina Caicedo ◽  
Aldo Rafael Vázquez-Arce ◽  
Omar Hernán Ossa ◽  
Hever De La Cruz ◽  
Alfredo Maciel-Cerda
Keyword(s):  
Tensile Strength ◽  
Flexural Strength ◽  
Microstructural Analysis ◽  
Weight Ratio ◽  
Extrusion Process ◽  
Injection Molding Process ◽  
Molding Process ◽  
Injection Process ◽  
Degradation Temperature ◽  
Mineral Fillers

In this work, a development of composites of polypropylene [PP] with mineral fillers [M] of talc and calcium carbonate [CaCO3] by co-extrusion and injection techniques were carried out. In the preparation of the mixtures, was used the rheometric analysis to define the optimum temperature of the extrusion process, and a weight ratio of 80:20 PP: fillers was maintained, while for the injection molding process six generations of PP and its compounds were obtained to study the rheological, thermal, morphological and mechanical properties of the new series of PPnM composites formed from a recycled matrix and the PPMn series reprocessed compounds for up to six cycles. The results allowed correlating the changes due to the thermal history and the influence of adding the mineral fillers. The mechanical characterization in the reprocessed matrix indicated a 6.0% decrease in tensile strength and an increase in flexural strength of 9.9%. Likewise, the compounds showed an increase in tensile strength of 11.7%, while flexural strength reached 35.8%. From the thermogravimetric analysis, the degradation temperature in the matrix gradually decreased from 406.5 °C to 364.3 °C, for the sixth generation with respect to the virgin material by the injection process; meanwhile, for the compounds was maintained around 410 °C indicating an optimal interaction, these results could be contrasted with the colorimetric analysis. Finally, re-injection led to a significant decrease in the size of the talc and CaCO3 particles; the sizes were estimated from microstructural analysis from Scanning Electron Microscope.

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