<p>Extrusion Deposition Additive Manufacturing (EDAM) is a process in which fiber-filled thermoplastic polymers are mixed and melted in an extruder and deposited onto a build plate in a layer-by-layer basis. Anisotropy caused by flow-induced orientation of discontinuous fibers along with the non-isothermal cooling process gives rise to internal stresses in printed parts which results in part deformation. The deformation and residual stresses can be abated by modifying the fiber orientation in the extrudate to best suit the print geometry. To that end, the focus of this research is on understanding the effect of fiber orientation state and fiber properties on effective properties of the printed bead and the final deformation of a part. The properties of three different orientation tensors of glass fiber-filled polyamide and carbon fiber-filled polyamide were experimentally and virtually characterized via micromechanics. A thermo-mechanical simulation framework developed in ABAQUS© was used to understand the effects of the varying fiber orientation tensor and fiber properties on the final deformation of printed parts. In particular, a medium-size geometry that is prone to high deformation was simulated and compared among the three orientation tensors and two material systems. This serves to be a good preliminary study to understand microscopic properties induced deformations in EDAM.</p>

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Thermoplastic prepregs that are also known as organo sheets are processed in presses and formed to half shells. Larger components can be produced by joining the half shells, which results in hollow bodies. However, current manufacturing technologies allow only cap profile shaped joints, which cause fiber deflections in the joint plane. This presentation shows that overlapping infrared welds in organo sheets enable weld strengths close to the interlaminar shear strengths of the unwelded materials and thus a fiber utilization across the joint plane. By using high welding pressures, a matrix depletion and a change of the fiber alignment in the weld plane may occur which causes low weld strengths. Therefore possibilbites to optimize the weld strengths are shown and one possible process variants for the manufacturing of hollow bodies by infrared welding is introduced.

Thermoplastic prepregs that are also known as organo sheets are processed in presses and formed to half shells. Larger components can be produced by joining the half shells, which results in hollow bodies. However, current manufacturing technologies allow only cap profile shaped joints, which cause fiber deflections in the joint plane. This paper shows that overlapping infrared welds in organo sheets enable weld strengths close to the interlaminar shear strengths of the unwelded materials and thus a fiber utilization across the joint plane. By using high welding pressures, a matrix depletion and a change of the fiber alignment in the weld plane may occur which causes low weld strengths. Therefore, criteria for the successful welding were defined and various possibilities to optimize the weld strengths were investigated.

従来型の繊維強化プラスチック(FRP)に対し環境負荷の少ない「グリーンコンポジット」の実用的な成形プロセスの確立が切望されている。本研究では、天然繊維およびポリ乳酸を原料とする長繊維強化樹脂(LFT)ペレット製造および射出成形による複合材製造法を対象に、複合材の力学的特性に対する繊維の含有水分や熱劣化の影響、繊維分散の効果等を把握し、高い特性を発揮させるための成形プロセスおよび諸条件を提示した。 / 'Green Composites' have been attracting attention due to their high sustainability and carbon neutrality. This study investigated the preparation process for composites of long jute fiber reinforced polylactic acid by LFT-pellet manufacturing method followed by injection molding. The author explored effect of several factors, such as moisture in fiber, heat decomposition of fiber at processing and the level of fiber dispersion in matrix resin, on mechanical properties of composites. The author eventually proposed the optimized process and operating windows for attaining higher mechanical properties of composites. / 博士(工学) / Doctor of Philosophy in Engineering / 同志社大学 / Doshisha University