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The manufacture of marine propellers in moulded anisotropic polymer compositesSearle, Timothy John January 1998 (has links)
This thesis examines the feasibility of manufacturing small marine propellers from continuous fibre reinforced polymer composite materials. An appraisal of some current applications of composite materials in the marine industry is given, together with the moves shown towards the use of composites in the area of propeller design. It has been shown that manufacturing propellers in composite materials is theoretically more cost effective than traditional materials. The manufacturing route investigated is Resin Transfer Moulding, where some detailed investigations have highlighted some of the critical processing parameters necessary for successful production of laminates suitable for propellers and other high performance marine structures. A thorough testing programme of 4 novel designs of composite propeller is reported. Trials at sea on university run vessels has enabled many hours use to be logged, which has shown the fitness for purpose of propellers made from glass reinforced, epoxy composite. Experimental tank testing has helped to shape the remainder of the research by identifying the possibility of using hydroelastic tailoring to improve the efficiency of the propeller when a variety of operating conditions are required from the propulsion system. Further experience is required with respect to the the tooling construction and the life assessment of the propeller. To facilitate appropriate modelling of the propeller, spreadsheet based load prediction models have been used. Finite element analysis (FEA) was used to model the elastic characteristics of one particular design of novel composite propeller. This indicated that traditional geometries may be too stiff to allow significant performance advantages from the anisotropy of the material. However the potential does exist for modified propeller geometries made from composite to give some performance benefit. For specific applications, small marine propellers made from continuous glass fibre reinforced epoxy composite are likely to yield cost savings over traditional propeller materials.
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Investigation of Heat Conduction Through PMC Components Made Using Resin Transfer MouldingSakka, Aymen 16 November 2012 (has links)
The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.
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Investigation of Heat Conduction Through PMC Components Made Using Resin Transfer MouldingSakka, Aymen 16 November 2012 (has links)
The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.
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Investigation of Heat Conduction Through PMC Components Made Using Resin Transfer MouldingSakka, Aymen January 2012 (has links)
The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.
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A technical and economical evaluation of RP technology for RTM toolingDippenaar, D. J. 03 1900 (has links)
Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2010. / ENGLISH ABSTRACT: This project investigates the use of Rapid Prototyping (RP), with specific focus
on Three Dimensional Printing (3DP), in the manufacture of complex shaped advanced
composite parts, using variants of the Resin Transfer Moulding (RTM)
method of composite manufacture. This study developed design guidelines, cost
models and a process chain by studying data obtained by making example parts,
from literature and consultation with industry. Advanced composite materials offer
some of the best low weight and high specific strength properties for the solution
of design problems. A major disadvantage of these processes, however, is the
low production rates possible and the need of costly moulds. The 3DP technologies
combined with the RTM composite process was found to enable a lowering
of costs and increase in productivity if smaller batch sizes are considered. The
most meaningful area of application for RP techniques seems to be for smaller
and more complex components. The geometrical freedom allowed by RP technologies
allowed the manufacture of parts which are challenging to manufacture
by conventional technology such as CNC machining. Example part case studies
were completed for a simple part utilising the one sided mould Resin Infusion
RTM variant as well as for a complex part utilising the closed mould Vacuum Assisted
Resin Transfer Moulding (VARTM) process variant. During these two case
studies it was clear that proper part infusion with resin is critical for the manufacture
of good quality composite parts free of voids and dry spots. It is possible to
improve the resin infusion by correct placement of resin inlet and outlet ports as
well as resin channels incorporated in the mould. Correct placement of these features
for the case studies was obtained through simulations done with RTM-Worx
software. Results also indicated that another useful application of RP technology
to RTM is the manufacture of disposable cores for parts with thick cross sections.
Resin channels were included on the surface of these cores to improve the mould
filling with resin and consequently part quality. An early cost estimation model,
based on the work of Veldsman (1995), was developed for the combined RP and
RTM manufacturing process. This model may help designers to eliminate expensive
design features and enables a quick cost comparison with competing processes.
Drawbacks of applying RP techniques to RTM include the limited lifetime
of moulds produced with 3DP and the size and accuracy limitations of the RP
t echnology. / AFRIKAANSE OPSOMMING: Hierdie projek handel oor die toepassing van die drie-dimensionele druk metode
van Snel-Prototipering (Rapid Prototyping) op die vervaardiging van komplekse
gevorderde saamgestelde materiaal komponente met die Hars-Inspuit Giet
(Resin Transfer Moulding) metode. Die projek behels die opstel van ontwerpsriglyne,
koste-modelle en ’n proses-ketting deur data te bestudeer wat bekom
is deur middel van die vervaardiging van eksperimentele parte, literatuurstudie
asook raadpleging met individue in die industrie. Gevorderde
saamgestelde materiale verskaf van die beste sterk, dog ligte oplossings vir sekere
ontwerpsprobleme. ’n Ernstige nadeel van hierdie materiale is egter die stadige
produksietempo moontlik en die vereiste van duur gietstukke. Die Snel-
Prototipering metodes, gekombineerd met ’n saamgestelde materiaal vervaardigingsproses,
maak laer kostes met beter produktiwiteit moontlik indien ontwerpers
die part grootte- en akkuraatheidsbeperkings in ag neem. Die mees betekenisvolle
area van toepassing blyk kleiner en meer komplekse komponente te
wees. Die vryheid in geometrie wat moontlik gemaak word deur die Snel-
Prototipering tegnologie laat die vervaardiging toe van parte wat uitdagend is om
te vervaardig met konvensionele tegnologie soos CNC masjinering. ’n Gevallestudie
is voltooi vir ’n eenvoudige part vervaardig met die enkelkant gietstuk
vakuum-infusie weergawe van die Hars-Inspuit Giet metode asook vir ’n komplekse
part wat vervaardig is met die geslote gietstuk Vakuum Hars-Inspuit Giet
weergawe van die basiese metode. Dit het tydens die twee gevallestudies duidelik
geword dat deeglike hars infusie van kritieke belang is vir die vervaardiging van
goeie kwaliteit parte sonder enige droë kolle of lugruimtes. Dit is moontlik om die
hars infusie te verbeter deur hars inlate en uitlate asook hars kanale in die korrekte
posisies te plaas. Die korrekte posisies vir hierdie komponente is verkry deur
middel van ’n reeks simulasies met die RTM-Worx sagteware. Resultate dui ook
daarop dat Snel-Prototipering tegnologie handig te pas kom by die vervaardiging
van verbruikbare kerne vir saamgestelde materiaal parte met groter diktes. Hars
kanale kan maklik op die kerne se oppervlak geskep word om die hars verspreiding
en gevolglik part kwaliteit te verbeter. ’n Vroeë kostevoorspellings model,
gebaseer op werk voltooi deur Veldsman (1995), is saamgestel vir die gekombineerde
Snel-Prototipering en Hars-Inspuit Giet proses. Hierdie model kan gebruik
word om duur ontwerpsbesonderhede op parte te elimineer en om ’n vinnige
koste vergelyking met ander vervaardigingsprosesse te toon. Nadele van die toepassing
van Snel-Prototipering tegnieke op Hars-Inspuit Giet sluit die beperkte
gietstuk-leeftyd en beperkte akkuraatheid in.
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Návrh křidélka z kompozitních materiálů / Design of Aileron of Composite MaterialsDvořák, Vlastimil January 2008 (has links)
This diploma thesis called „Aileron Design of Composite Materials” deals with the technologies of production used in aricraft industries. It shows appropriate conceptions of composite structures for the airplane aileron of Aero L-159A/B as well as a proposal of an accetable structure for RTM process.
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An experimental cost model for composite parts using vacuum assisted resin transfer moulding (VARTM)Vogt, Christian 03 1900 (has links)
Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2011. / ENGLISH ABSTRACT: Vacuum assisted resin transfer moulding (VARTM) belongs to the category of resin infusion
techniques that use lower than atmospheric pressure to infiltrate a reinforced cavity. This
technique has various advantages; however, manufacturing costs can be relatively high due to
more difficult shapes fabricated and a lack of knowledge regarding cost driving factors.
The objective of this study was to develop a cost model for composite parts. Such a model
allows the estimation of manufacturing costs of shapes of different geometries. Therefore, it
provides a comparison to alternative manufacturing techniques, such as metal forming or
composite spray lay-up and helps to avoid unnecessarily expensive design features. The
proposal was made to split complex shaped composite parts into individual basic shapes,
which are further investigated here.
For the basic shapes, an experimental approach was used where the manufacturing times of
each process step are measured and then statistically analysed. Infusion simulation software
was used to obtain additional filling times to complete the design of experiments. This method
allows the estimation of manufacturing times of composite parts with different geometries.
The manufacturing times were validated to that of a complex shaped industrial part, with
reasonable results. Finally, a flexible cost model was developed to compare different
manufacturing techniques and to estimate the manufacturing costs. / AFRIKAANSE OPSOMMING: Vakuumgesteunde harsinspuitingsgietwerk (VARTM) behoort tot die kategorie
harsinspuitingstegnieke wat laer-as-atmosferiese druk gebruik om ʼn versterkte holte binne te
dring. Hierdie tegniek hou verskeie voordele in. Tog kan vervaardigingskoste betreklik hoog
wees wanneer dit by ingewikkelder vorms en ʼn gebrek aan kennis met betrekking tot
kostesnellers kom.
Die doelwit van hierdie studie was om ʼn kostemodel vir saamgestelde onderdele te ontwikkel.
Die model maak voorsiening vir die raming van die vervaardigingskoste vir verskillende
afmetings. Sodoende bied dit ʼn vergelyking met alternatiewe tegnieke, en help voorkom
onnodig duur ontwerpkenmerke. Daar is voorgestel dat dele met ingewikkelde vorms in
individuele basiese vorms verdeel word, wat dan hier verder ondersoek word.
Vir die basiese vorms word ʼn eksperimentele benadering gebruik waar die vervaardigingstye
in elke prosesstap gemeet en statisties ontleed word. Voorts word
inspuitingsimulasiesagteware gebruik om komplementêre inspuitingstye te bepaal ten einde
die eksperimentele ontwerp te voltooi. Hierdie metode maak dit ook moontlik om die
vervaardigingstye vir saamgestelde materiaal onderdele van verskillende afmetings te raam.
Die vervaardigingstye word dan bevestig aan die hand van dié van ʼn kompleks gevormde
industriële onderdeel, met redelike resultate. Uiteindelik word ʼn buigsame kostemodel
ontwikkel om verskillende vervaardigingstegnieke te vergelyk en die vervaardigingskoste te
raam.
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Energy Efficient Composites for Automotive Industry.Rojas, Mariana January 2021 (has links)
Hybrid composites play a key role in sustainable development. For many years, carbon fibres in an epoxy matrix have been an attractive option for many structural applications because of their higher specific mechanical properties mostly. However, recycling and sustainability are some of the composite shortcomings; and in that context, natural fibres have gained popularity. The present study aimed to design and manufacture short carbon/flax hybrid composites. Two different arrangements were chosen: random and layers configuration. Resin Transfer Moulding (RTM) was used to fabricate these hybrid composites. Mechanical tests and optical microscopy technique were conducted to understand the effect of the interaction of these two different reinforcements. Mechanical tests showed a remarkable difference between the hybrid configurations under flexural loadings. Furthermore, outstanding property values were observed in the hybrid configurations compared to single fibre composites. The resultant materials have seemed an attractive combination of fibres with a remarkable balance between mechanical performance and eco-friendliness.
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Desenvolvimento de um equipamento de moldagem por transferência de resina para uso laboratorial.MIRANDA, Bruno Moura. 25 April 2018 (has links)
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Previous issue date: 2015-02-27 / O objetivo deste trabalho foi desenvolver um equipamento de injeção de resina para processar compósitos via moldagem por transferência de resina de uso laboratorial. Foi cumprida a seguinte metodologia: concepção, fabricação e testes no equipamento, testes de injeção nas estações de processamento, fabricação de placas compósitas e posterior caracterização. Os materiais utilizados nos experimentos foram: Manta de fibra de vidro (450g/m2), tecido básico de fibra de vidro (600 g/m2) e resina poliéster insaturada ortofitálica de média viscosidade Arazyn 1.0 #08 Ara Ashland ® e catalisador Butanox 50. Foram produzidas placas de pequena área, com dimensões de: 175x125x5mm e de grande área, com dimensões de: 340x340x5mm. Baseado nos experimentos resultados, conclui-se que foi possível o projeto, desenvolvimento e fabricação de um equipamento de injeção de resina por RTM de uso laboratorial, de baixo custo, com baixas perdas energéticas, para fabricação de compósitos com reforço dos tipos: manta e tecido, com diferentes gramaturas e pequena espessura. / The objective of this work was design a laboratorial Resin Transfer Moulding Equipment to process composites. The following methodology was fulfilled: Design and manufacture of the equipment, testing its process capabilities, injection tests in the processing stations, manufacturing of composite plates and further characterization. The materials used in the experiments were glass fiber mat (450g / m2), base glass fiber fabric (600 g / m2), a medium viscosity 1.0 Arazyn Ara Ashland ® # 08 unsaturated polyester resin and 50 Butanox. Small and large area plates were produced with dimensions of: 175x125x5mm and 340x340x5mm respectively. Based on the experiments results, it is concluded that it was possible the design, development and manufacture of a resin injection equipment RTM for laboratory use with low cost and low energy losses, for the manufacture of composites with two reinforcement kind: mat and fabric, with different weights and thin.
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FRP i brokonstruktion : -varför används FRP inte i SverigeEriksson, Carl-Johan, Erlingsson, Jonas January 2015 (has links)
FRP stands for Fiber Reinforced Polymer. FRP materials have yet to be introduced inbridge construction in Sweden. Composite materials can through combined componentsand manufacturing processes be tailored to fit advanced bridge designs. FRP materials arestrong, durable and of low weight. FRP materials give the superstructure reduced weightand are therefore a suitable alternative for industrial prefabrication. This report shows thatFRP materials are possible to use in bridge construction. With the introduction of a specificEurocode we are confident that FRP materials will become a competitive alternative inbridge construction in Sweden in the future. / Broar är förenade med stora kostnader, dels för att bygga och dels för att underhålla ochreparera. FRP står för Fiber Reinforced Polymer är ett erkänt material för många andraanvändningsområden, exempelvis flyg och bilindustri. I Europa finns en mängd FRP-broar,men materialet har ännu inte introducerats i någon bro i Sverige.FRP är ett kompositmaterial som genom olika kombinationer av komponenter ochtillverkningsprocesser kan skräddarsys för den aktuella uppgiften i en konstruktion. FRPmaterialär starka, beständiga och har en låg vikt. Fördelar med FRP inom brokonstruktionär att det ger överbyggnaden en minskad egenvikt och därmed är ett lämpligt alternativ attprefabricera industriellt, då bland annat transport- och lyftbarhet gynnas samt att en högbeständighet ger minskat underhåll.Då ingen litteratur hanterar FRP i Brokonstruktion har de intervjuades åsikter varit mycketviktiga för arbetet. Litteraturstudien har legat till grund för en ökad förståelse för egenskaperutmärkande för olika typer av FRP. Intervjuer har utförts med personer som i dagslägetkommit i kontakt med materialet inom brokonstruktion. Detta har gjorts för att nå ett relevantresultat med möjlighet att kunna identifiera materialets för- respektive nackdelar samtanledningen till det låga användandet i Sverige.Rapporten visar att materialet har positiva egenskaper och är möjligt att använda vidkonstruktion av broar. Det saknas i dagsläget en specifik Eurokod som på ett enhetligt sättredovisar hur materialet ska hanteras. Med införandet av en specifik Eurokod och om en nykompetens arbetas fram inom branschen är vi övertygade om att FRP-material kommer attbli ett konkurrenskraftigt alternativ vid brokonstruktion.
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