Cargando…
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...
Autores principales: | , , , , , |
---|---|
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 |
_version_ | 1784582908447555584 |
---|---|
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. |
format | Online Article Text |
id | pubmed-8512096 |
institution | National Center for Biotechnology Information |
language | English |
publishDate | 2021 |
publisher | MDPI |
record_format | MEDLINE/PubMed |
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 |
work_keys_str_mv | AT chenlu anumericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT dengtianzhengxiong anumericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT zhouhelezi anumericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT huangzhigao anumericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT pengxiongqi anumericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT zhouhuamin anumericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT chenlu numericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT dengtianzhengxiong numericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT zhouhelezi numericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT huangzhigao numericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT pengxiongqi numericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites AT zhouhuamin numericalsimulationmethodfortheonestepcompressionstampingprocessofcontinuousfiberreinforcedthermoplasticcomposites |