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A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites

Continuous fiber reinforced thermoplastic (CFRTP) composites have many advantages, such as high strength, high stiffness, shorter cycle, time and enabling the part consolidation of structural components. However, the mass production of the CFRTP parts is still challenging in industry and simulations...

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Autores principales: Chen, Lu, Deng, Tianzhengxiong, Zhou, Helezi, Huang, Zhigao, Peng, Xiongqi, Zhou, Huamin
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8512096/
https://www.ncbi.nlm.nih.gov/pubmed/34641053
http://dx.doi.org/10.3390/polym13193237
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author Chen, Lu
Deng, Tianzhengxiong
Zhou, Helezi
Huang, Zhigao
Peng, Xiongqi
Zhou, Huamin
author_facet Chen, Lu
Deng, Tianzhengxiong
Zhou, Helezi
Huang, Zhigao
Peng, Xiongqi
Zhou, Huamin
author_sort Chen, Lu
collection PubMed
description Continuous fiber reinforced thermoplastic (CFRTP) composites have many advantages, such as high strength, high stiffness, shorter cycle, time and enabling the part consolidation of structural components. However, the mass production of the CFRTP parts is still challenging in industry and simulations can be used to better understand internal molding mechanisms. This paper proposes a three-dimensional simulation method for a one-step compression-stamping process which can conduct thermoplastic compression molding and continuous fiber reinforced thermoplastic composite stamping forming in one single mold, simultaneously. To overcome the strongly coupled non-isothermal moving boundary between the polymer and the composites, arbitrary Lagrangian–Eulerian based Navier–Stokes equations were applied to solve the thermoplastic compression, and a fiber rotation based objective stress rate model was used to solve for the composite stamping. Meanwhile, a strongly coupled fluid structure interaction framework with dual mesh technology is proposed to address the non-isothermal moving boundary issue between the polymer and the composites. This simulation method was compared against the experimental results to verify its accuracy. The polymer flow fronts were measured at different molding stages and the error between simulation and experiment was within 3.5%. The final composites’ in-plane deformation error was less than 2.5%. The experiment shows that this work can accurately simulate the actual molding process.
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spelling pubmed-85120962021-10-14 A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites Chen, Lu Deng, Tianzhengxiong Zhou, Helezi Huang, Zhigao Peng, Xiongqi Zhou, Huamin Polymers (Basel) Article Continuous fiber reinforced thermoplastic (CFRTP) composites have many advantages, such as high strength, high stiffness, shorter cycle, time and enabling the part consolidation of structural components. However, the mass production of the CFRTP parts is still challenging in industry and simulations can be used to better understand internal molding mechanisms. This paper proposes a three-dimensional simulation method for a one-step compression-stamping process which can conduct thermoplastic compression molding and continuous fiber reinforced thermoplastic composite stamping forming in one single mold, simultaneously. To overcome the strongly coupled non-isothermal moving boundary between the polymer and the composites, arbitrary Lagrangian–Eulerian based Navier–Stokes equations were applied to solve the thermoplastic compression, and a fiber rotation based objective stress rate model was used to solve for the composite stamping. Meanwhile, a strongly coupled fluid structure interaction framework with dual mesh technology is proposed to address the non-isothermal moving boundary issue between the polymer and the composites. This simulation method was compared against the experimental results to verify its accuracy. The polymer flow fronts were measured at different molding stages and the error between simulation and experiment was within 3.5%. The final composites’ in-plane deformation error was less than 2.5%. The experiment shows that this work can accurately simulate the actual molding process. MDPI 2021-09-24 /pmc/articles/PMC8512096/ /pubmed/34641053 http://dx.doi.org/10.3390/polym13193237 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Chen, Lu
Deng, Tianzhengxiong
Zhou, Helezi
Huang, Zhigao
Peng, Xiongqi
Zhou, Huamin
A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites
title A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites
title_full A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites
title_fullStr A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites
title_full_unstemmed A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites
title_short A Numerical Simulation Method for the One-Step Compression-Stamping Process of Continuous Fiber Reinforced Thermoplastic Composites
title_sort numerical simulation method for the one-step compression-stamping process of continuous fiber reinforced thermoplastic composites
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8512096/
https://www.ncbi.nlm.nih.gov/pubmed/34641053
http://dx.doi.org/10.3390/polym13193237
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