| An ideal introductory text, this book helps readers understand and improve current manufacturing processes as well as invent novel composite processing techniques. It includes qualitative questions and fill-in-the-blank exercises along with quantitative problems. The contents covers transport equations especially geared towards polymer flows, the basics of fluid mechanics and heat transfer principles, short fiber suspension and advanced thermoplastic manufacturing methods, reaction and crystallization kinetics and permeability of fabrics, conventional assumptions in polymer composite processing, and modeling tools such as dimensionless analysis and closed forms solutions. Table of Contents Preface 1 Introduction 1 1.1 Motivation and Contents 1 1.2 Preliminaries 2 1.3 Polymer Matrices for Composites 4 1.4 Fibers 11 1.5 Classification 13 1.6 General Approach to Modeling 16 1.7 Organization of the Book 18 1.8 Exercises 18 2 Overview of Manufacturing Processes 23 2.1 Background 23 2.2 Classification Based on Dominant Flow Process 24 2.3 Short Fiber Suspension Manufacturing Methods 25 2.4 Advanced Thermoplastic Manufacturing Methods 37 2.5 Advanced Thermoset Composite Manufacturing Methods 46 2.6 Exercises 54 3 Transport Equations for Composite Processing 63 3.1 Introduction to Process Models 63 3.2 Conservation of Mass (Continuity Equation) 64 3.3 Conservation of Momentum (Equation of Motion) 70 3.4 Stress-Strain Rate Relationship 75 3.5 Examples on Use of Conservation Equations to Solve Viscous Flow Problems 84 3.6 Conservation of Energy 95 3.7 Exercises 107 4 Constitutive Laws and Their Characterization 111 4.1 Introduction 111 4.2 Resin Viscosity 112 4.3 Viscosity of Aligned Fiber Thermoplastic Laminates 121 4.4 Suspension Viscosity 129 4.5 Reaction Kinetics 137 4.6 Crystallization Kinetics 146 4.7 Permeability 151 4.8 Fiber Stress 161 4.9 Exercises 164 5 Model Simplifications and Solution 173 5.1 Introduction 173 5.2 Formulation of Models 175 5.3 Model and Geometry Simplifications 180 5.4 Dimensionless Analysis and Dimensionless Numbers 183 5.5 Customary Assumptions in Polymer Composite Processing 198 5.6 Boundary Conditions for Flow Analysis 201 5.7 Convection of Variables 205 5.8 Process Models from Simplified Geometries 206 5.9 Mathematical Tools for Simplification 211 5.10 Solution Methods 216 5.11 Numerical Methods 219 5.12 Validation 221 5.13 Exercises 223 6 Short Fiber Composites 227 6.1 Introduction 227 6.2 Compression Molding 229 6.3 Extrusion 255 6.4 Injection Molding 265 6.5 Exercises 285 7 Advanced Thermoplastic Composite Manufacturing Processes 291 7.1 Introduction 291 7.2 Composite Sheet Forming Processes 292 7.3 Pultrusion 299 7.4 Thermal Model 308 7.5 On-line Consolidation of Thermoplastics 311 7.6 Exercises 333 8 Processing Advanced Thermoset Fiber Composites 339 8.1 Introduction 339 8.2 Autoclave Molding 340 8.3 Liquid Composite Molding 356 8.4 Filament Winding of Thermosetting Matrix Composites 393 8.5 Summary and Outlook 402 8.6 Exercises 403 Bibliography 409 Index 433 |
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