CURE SIMULATION OF LARGE RUBBER COMPONENTS: A COMPARISON OF COMPRESSION AND EXTRUSION MOLDING

2012 ◽  
Vol 85 (4) ◽  
pp. 495-512 ◽  
Author(s):  
Marina Fernando ◽  
Wong Hon Fei ◽  
Colin Hull
Keyword(s):  
Cycle Time ◽  
Cure Kinetics ◽  
Compression Molding ◽  
The State ◽  
Simulation Data ◽  
Element Analysis ◽  
Manufacturing Method ◽  
Cure Time ◽  
Thin Walled ◽  
Product Manufacture

ABSTRACT Curing rubber is a complex process that involves the insertion of cross-links to convert the rubber into a useful functional material. The estimation of the cure time needed for product manufacture of small or thin walled products is often arrived at by means of a rheometer trace. Although this has been recognized as adequate for thin walled products, the production of large rubber articles requires a more rigorous analysis of cure kinetics for an essentially non-isothermal process. Often finite element analysis is used to generate non-isothermal temperature histories in a thick component, and then an appropriate cure kinetic equation is solved to predict the state of cure. In addition to generating the capability for cure time prediction, there is a need in the industry to minimize cycle time, improving productivity and therefore costs involved in product manufacture. For large products, the viability of the use of extrusion molding, where the rubber is extruded into a heated mold at the same temperature as the mold, has been demonstrated in previous reported work in this laboratory. The present work explores, via simulation, the feasibility of using extrusion molding as a manufacturing method for large components. The cure simulation module of Autodesk Moldflow has been used to compare the state of cure of a laminated bearing manufactured by conventional compression molding and extrusion molding. Previous experimental data on the temperature histories of a large laminated bearing manufactured using compression molding are compared with simulation data. Simulation data are then presented on manufacturing the bearing using extrusion molding. The aim is to demonstrate the usefulness of extrusion molding for very large components and to illustrate the advantages of using simulation codes to assist in shortening the cycle time in product manufacture.

scholarly journals Simulation-Based Optimization of Cure Cycle of Large Area Compression Molding for LED Silicone Lens

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Min-Jae Song ◽  
Kwon-Hee Kim ◽  
Seok-Kwan Hong ◽  
Jeong-Won Lee ◽  
Jeong-Yeon Park ◽  
...  
Keyword(s):  
Cycle Time ◽  
Three Dimensional ◽  
Cure Kinetics ◽  
Compression Molding ◽  
Silicone Resin ◽  
Large Area ◽  
Molding Process ◽  
Temperature Deviation ◽  
Cure Model ◽  
Cure Cycle

Three-dimensional heat transfer-curing simulation was performed for the curing process by introducing a large area compression molding for simultaneous forming and mass production for the lens and encapsulants in the LED molding process. A dynamic cure kinetics model for the silicone resin was adopted and cure model and analysis result were validated and compared through a temperature measurement experiment for cylinder geometry with cure model. The temperature deviation between each lens cavity could be reduced by implementing a simulation model on the large area compression mold and by optimizing the location of heat source. A two-step cure cycle was constructed to reduce excessive reaction peak at the initial stage and cycle time. An optimum cure cycle that could reduce cycle time by more than 29% compared to a one-step cure cycle by adjusting dwell temperature, heating rate, and dwell time was proposed. It was thus confirmed that an optimization of large area LED lens molding process was possible by using the present experiment and the finite element method.

Decreasing the cycle time for in‐mold coating (IMC) of sheet molding compound (SMC) compression molding

2019 ◽  
Vol 59 (6) ◽  
pp. 1158-1166 ◽  
Author(s):  
Mohammad S.K. Bhuyan ◽  
Seunghyun Ko ◽  
Maria G. Villarreal ◽  
Elliott J. Straus ◽  
Lee James ◽  
...  
Keyword(s):  
Cycle Time ◽  
Compression Molding ◽  
Molding Compound ◽  
Sheet Molding Compound

Stresses Around Wellbores in Nonlinear Rock

1968 ◽  
Vol 8 (03) ◽  
pp. 304-312 ◽  
Author(s):  
M.A. Mahtab ◽  
R.E. Goodman
Keyword(s):  
Finite Element Analysis ◽  
Principal Stress ◽  
Intermediate Principal Stress ◽  
The State ◽  
Initial Stresses ◽  
Stress Strain ◽  
Element Analysis ◽  
Deviator Stress ◽  
State Of Stress ◽  
Strain Data

ABSTRACT The state of stress around a vertical wellbore in rock following nonlinear stress-strain laws is examined by means of finite element analysis. The wellbore is considered an axisymmetric body with axisymmetric loading. The initial vertical and horizontal stresses are "locked" in the rock elements around the wellbore and a new state of stress is generated by the displacements which occur around the borehole. A point-wise variation of the elastic moduli is made on the basis of the new stress state and the triaxial data. The initial stresses are now reintroduced along with the changed moduli and original boundary constraints. This procedure is repeated until convergent stresses are reached. The effect of nonlinearity on stresses is examined for a 6,000-ft wellbore in a schistose gneiss and Berea sandstone using results of laboratory triaxial compression tests. The results show that the effect is restricted to one well radius from the bottom periphery of the hole. Beyond a distance of one-quarter radius, the effect of nonlinearity on stresses is almost always less than 5 percent for the cases considered. The consideration of a static pressure inside the well does not magnify the effect of nonlinearity on borehole stresses. INTRODUCTION The terms "wellbore" and "borehole" here designate cylindrical openings in the ground with vertical axis and a circular cross-section. A knowledge of the stress redistribution that occurs on excavating a wellbore is important in understanding the behavior of the lined or unlined hole, hydraulic fracture response, and the effect of stress redistribution on drillability; also it is important in predicting initial stresses in the virgin ground, and in analyzing the response of measuring instruments placed in the borehole. Our knowledge of the state of stress around a wellbore has been restricted to homogeneous, isotropic, elastic material and derives chiefly from the analysis by Miles and Topping1 and the photoelastic work of Galle and Wilhoit2 and Word and Wilhoit.3 In this investigation the state of stress is examined for a nonlinear elastic material by means of finite element analysis. Many rocks possess stress-strain curves that depart notably from straight lines in their initial or final portions. While the literature contains abundant stress-strain data from triaxial tests (axisymmetric loading) on cylindrical rock specimens, there is little information on rock deformability under nonaxisymmetric loading conditions such as occur at each point around the bottom of a wellbore. Although there is some knowledge of the effect of intermediate principal stress on rock strength, there is virtually nothing known about its effect on rock deformability; therefore, we have assumed here that the effect of intermediate principal stress can be ignored. A schistose gneiss4 and Berea sandstone5 were selected as representative rocks for this analysis. The traditional graphs of deviator stress (s1-s3) vs axial strain were reworked to give the tangent modulus as a function of the deviator stress for varying values of the minor principal stress. The result is a nesting family of skewed, bell-shaped curves for the gneiss (Fig. 1A) and the sandstone (Fig. 2A). A similar replotting of the lateral strain data defines the variation of Poisson's ratio (?) with the deviator stress and confining pressure. These curves, shown in Fig. 1B for the gneiss and in Fig. 2B for the sandstone, are not so well ordered as the tangent modulus curves. However, all of these display an increase of ? with deviator stress application, but the rate of increase diminishes with confinement. The ET and ? curves for the two rock types are tabulated in Tables 1A and 1B for use in a digital computer so that material properties corresponding to a given state of stress can be assigned by interpolation.

scholarly journals Flexural-Torsional Vibration of Thin-Walled Beams Subjected to Combined Initial Axial Load and End Bending Moment: Application to the Design of Saw Tooth Blades

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Van Binh Phung ◽  
Anh Tuan Nguyen ◽  
Hoang Minh Dang ◽  
Thanh-Phong Dao ◽  
V. N. Duc
Keyword(s):  
Boundary Conditions ◽  
Axial Load ◽  
Stability Boundary ◽  
Bending Moment ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Rayleigh Method ◽  
Thin Walled ◽  
The Stability ◽  
Fixed End

The present paper analyzes the vibration issue of thin-walled beams under combined initial axial load and end moment in two cases with different boundary conditions, specifically the simply supported-end and the laterally fixed-end boundary conditions. The analytical expressions for the first natural frequencies of thin-walled beams were derived by two methods that are a method based on the existence of the roots theorem of differential equation systems and the Rayleigh method. In particular, the stability boundary of a beam can be determined directly from its first natural frequency expression. The analytical results are in good agreement with those from the finite element analysis software ANSYS Mechanical APDL. The research results obtained here are useful for those creating tooth blade designs of innovative frame saw machines.

scholarly journals Simplified and Accurate Stiffness of a Prismatic Anisotropic Thin-Walled Box

2018 ◽  
Vol 12 (1) ◽  
pp. 1-20 ◽  
Author(s):  
Giacomo Canale ◽  
Felice Rubino ◽  
Paul M. Weaver ◽  
Roberto Citarella ◽  
Angelo Maligno
Keyword(s):  
Cross Sections ◽  
Torsional Stiffness ◽  
Element Analysis ◽  
Cross Sectional ◽  
Analysis And Design ◽  
Proposed Model ◽  
Vertical Walls ◽  
Thin Walled ◽  
High Level ◽  
Realistic Geometries

Background:Beam models have been proven effective in the preliminary analysis and design of aerospace structures. Accurate cross sectional stiffness constants are however needed, especially when dealing with bending, torsion and bend-twist coupling deformations. Several models have been proposed in the literature, even recently, but a lack of precision may be found when dealing with a high level of anisotropy and different lay-ups.Objective:A simplified analytical model is proposed to evaluate bending and torsional stiffness of a prismatic, anisotropic, thin-walled box. The proposed model is an extension of the model proposed by Lemanski and Weaver for the evaluation of the bend-twist coupling constant.Methods:Bending and torsional stiffness are derived analytically by using physical reasoning and by applying bending and torsional stiffness mathematic definition. Unitary deformations have been applied when evaluation forces and moments arising on the cross section.Results:Good accuracy has been obtained for structures with different geometries and lay-ups. The model has been validated with respect to finite element analysis. Numerical results are commented upon and compared with other models presented in literature.Conclusion:For cross sections with a high level of anisotropy, the accuracy of the proposed formulation is within 2% for bending stiffness and 6% for torsional stiffness. The percentage of error is further reduced for more realistic geometries and lay-ups.The proposed formulation gives accurate results for different dimensions and length rations of horizontal and vertical walls.

Computational Modeling and Energy Absorption Behavior of Thin-Walled Tubes with the Kresling Origami Pattern

2021 ◽  
Vol 62 (2) ◽  
pp. 71-81
Author(s):  
Jiaqiang Li ◽  
Yao Chen ◽  
Xiaodong Feng ◽  
Jian Feng ◽  
Pooya Sareh
Keyword(s):  
Energy Absorption ◽  
Material Properties ◽  
Rotation Angle ◽  
Programming Model ◽  
Mixed Integer ◽  
Element Analysis ◽  
Cross Sectional ◽  
Thin Walled Tube ◽  
Absorption Performance ◽  
Thin Walled

Origami structures have been widely used in various engineering fields due to their desirable properties such as geometric transformability and high specific energy absorption. Based on the Kresling origami pattern, this study proposes a type of thin-walled origami tube the structural configuration of which is found by a mixed-integer linear programming model. Using finite element analysis, a reasonable configuration of a thin-walled tube with the Kresling pattern is firstly analyzed. Then, the influences of different material properties, the rotation angle of the upper and lower sections of the tube unit, and cross-sectional shapes on the energy absorption behavior of the thin-walled tubes under axial compression are evaluated. The results show that the symmetric thin-walled tube with the Kresling pattern is a reasonable choice for energy absorption purposes. Compared with thin-walled prismatic tubes, the thin-walled tube with the Kresling pattern substantially reduces the initial peak force and the average crushing force, without significantly reducing its energy absorption capacity; moreover, it enters the plastic energy dissipation stage ahead of time, giving it a superior energy absorption performance. Besides, the material properties, rotation angle, and cross-sectional shape have considerable influences on its energy absorption performance. The results provide a basis for the application of the Kresling origami pattern in the design of thin-walled energy-absorbingstructures.

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