A razão da existência de um molde-protótipo é de se obter rapidamente um injetado com o mesmo material e utilizando o mesmo processo de fabricação do produto final, com baixo custo. Seus injetados podem servir como protótipos, lotes pilotos, pré-séries ou ainda cobrirem a necessidade de uma baixa demanda de produto ou de pequenos lotes. Critérios de manufaturabilidade e de qualidades mecânicas são importantes na fabricação do molde-protótipo. Entretanto, além destes critérios, este molde deve ser capaz de produzir um injetado com qualidade semelhante ao produto injetado em um molde convencional. Observa-se, no entanto, que são escassos os estudos referentes à utilização de material alternativo para molde-protótipo e a influência deste material no produto injetado. Desta forma, o objetivo principal deste estudo é caracterizar um molde-protótipo usinado em liga de zinco (zamac-8), através da análise das propriedades físicas (Microscopia Eletrônica de Varredura com Energia Dispersiva de Raio-X, MEV-EDS) e mecânicas (Ensaios de Tração e Flexão) do polipropileno (PP) injetado nesta ferramenta e compará-lo ao injetado em aço. Os resultados demonstram que o PP injetado em zamac-8 possui características similares ao moldado em aço, sem apresentar contaminação. Assim, este material pode ser recomendado para esta finalidade. / The reason for the existence of a prototype mold is to obtain a quickly injected with the same material and using the same manufacturing process of the final product with low cost. Their models can serves as prototypes, pilot batches, preseries or the need to cover a lower demand for products or small batches. Criteria for manufacturability and mechanical qualities are important in the manufacture of prototype mold, but these criteria are only valid if this mold is capable of producing injected with a similar quality to the product injected into a conventional mold. However, there are few studies concerning the use of alternative material for prototype mold and the influence of that material into the product injected. Thus, the main objective of this study is to characterize a prototype mold machined in zinc alloy (Zamak-8), by analyzing the physical properties and mechanical properties of the polypropylene (PP) injected into this tool and compare it injected into the steel. The results show that the PP injected into zamac-8 has characteristics similar to the injected in steel mold, without contamination. Thus, this material can be recommended for the purpose for injection mold.

Les agro-composites font l'objet de nombreuses études et applications industrielles en raison des multiples propriétés mécaniques qu'ils présentent. Ces propriétés présentent de grandes perspectives comparées à celles des composites traditionnels. Cependant les connaissances sur le comportement mécanique de l'interface fibre/matrice restent limitées. De plus, la différence de propriété entre la fibre hydrophile et la matrice hydrophobe peut causer des défauts au niveau de l’interface. Il est donc important de caractériser finement la décohésion à l'interface au cours d'une sollicitation. Plusieurs méthodes ont été proposées dans la littérature, elles sont généralement très complexes à mettre en œuvre et sont coûteuses. Dans cette étude, nous avons développé une méthode de caractérisation en se basant sur l'essai de « pull-out ». La géométrie de la fibre a été prise en compte dans le calcul des propriétés mécaniques de l'interface par la mise à profit d'une approche inspirée de la tomographie. L'influence de la température d'élaboration sur les propriétés mécaniques de l'interface a été étudiée de manière à définir la température optimale. L'évolution des propriétés interfaciales a été suivie au cours d'un vieillissement en humidité relative. Après quatre semaines, la résistance au cisaillement et la rigidité au cisaillement de l'interface sont diminuées fortement alors que la déformation à la rupture est augmentée / Agro-composites are increasingly studied and applied to various industries over recent years due to good mechanical properties compared to conventional composites especially in terms of specific values. However, since low adhesion between the hydrophilic fiber and hydrophobic matrix, which occurs one of the main breaks modes in this kind of material, the characterization of the interface becomes a key problem. For investigation of this issue, existing methods show limitation for reasons of complexity (in preparation, in principle) and of cost. In this study, we developed a « pull-out ». In particular, the real fiber geometry of the plant fiber was taken into the calculation of mechanical properties of interface using a tomography inspired method. By checking the effective temperature of the molding then varying it, we studied the effect of this processing parameter to mechanical properties of fibre/matrix interface and determined the optimal conditions. The developed experimental protocol is applied to aged interfaces in order to clarifying the evolution of interfacial properties during the aging time to relative humidity. After four weeks, the interfacial shear strength and the shear modulus of the interface were greatly reduced while the shear deformation at the rupture was greatly increased

Continuous fibre-reinforced thermoplastics often are offered as impregnated and consolidated semi-finished products which are known as organic sheets. The thermoplastic matrix leads to several advantages including the thermoformability and weldability. Parts made of organic sheets are frequently produced by forming the semi-finished product into half-shells and stiffening those shells in the course of the process e.g. by the injection moulding of ribs. Larger and more complex parts with hollow body structures can be manufactured e.g. by forming the semi-finished products into half-shells and joining the half-shells. However, the currently available manufacturing technologies for parts made of organic sheets have cap profile shaped joints which prevent the use of the reinforcing fibres across the joint plane. Investigations have proven that overlapping weld joints in organic sheets show much higher strengths than cap profile shaped joints which can be explained by the fibre use across the joint plane. Furthermore, the infrared welding technology was verified as an appropriate process for the welding of organic sheets since no need for additional welding material is given, short heating times can be realized and no contact of the infrared emitters to the joining parts is required. Therefore, the present study shall reveal the high potential of the overlapping welding of organic sheets. Influences on the weld strengths of infrared welded organic sheets are described and potential improvements concerning the materials to be welded as well as the welding process are shown.

Endlosfaserverstärkte Thermoplaste werden oftmals als imprägnierte und konsolidierte Halbzeuge angeboten. Solche thermoplastischen Prepregs werden üblicherweise als Organobleche bezeichnet. Die thermoplastische Matrix ermöglicht unter anderem die Warmformbarkeit und Schweißbarkeit von Organoblechen. Organobleche sind, durch die ausschließliche Möglichkeit sie mittels Thermoformen umzuformen, in ihrer Formgebung auf halbschalige Strukturen beschränkt, welche begrenzte Torsions-, Verwindungs- und Beulsteifigkeiten aufweisen. Um die Steifigkeiten dieser schalenförmigen, offenen Bauteile zu erhöhen, können z. B. versteifende Rippen oder Verstärkungssegmente eingebracht werden. Aufgrund des Thermoformprozesses sind mit Organoblechen, verglichen mit duroplastischen Systemen, jedoch nur kleine und einfache Bauteilgeometrien realisierbar. Um neben der Steifigkeitserhöhung auch größere und komplexere Bauteile herzustellen, können die schalenförmigen Organobleche während des Umformvorgangs gefügt werden. Auf diese Weise werden Hohlkörper in Doppelhutprofilform gefertigt. So werden, auch ohne Einbringung von Rippen o. ä., hohe Bauteilsteifigkeiten erreicht. Die Doppelhutprofilform hat jedoch eine nicht optimale Nutzung der Faserverstärkung über die Fügeebene hinweg zur Folge, da die Fasern von der Belastungsrichtung abweichend umgelenkt werden. Im vorliegenden Beitrag wird daher das überlappende Infrarotschweißen von Organoblechen behandelt, was eine Faserverstärkung über die Fügeebene hinweg ermöglicht. Die Prozess- und Werkstoffeinflüsse auf die Verbindungseigenschaften werden beschrieben und Möglichkeiten zur Optimierung der Schweißnahteigenschaften dargestellt. Des Weiteren werden Optimierungskriterien für überlappende Infrarotschweißungen an den untersuchten Organoblechen festgelegt. Die im Verlauf der Forschungsarbeiten umzusetzenden Verfahrensvarianten zur Herstellung von Hohlkörperbauteilen aus Organblechen werden zudem vorgestellt.

The design of traction mechanisms of continuous conveying units (e. g. plastic chains) is so far based on a purely mechanical dimensioning. However, mechanical limits are only applicable in a limited way to avoid system failure. With higher speeds or pressure, especially the thermal stress increases, which results in system failure based on softening or melting of the materials at a certain temperature. By means of systematic studies, correlations between friction temperature, coefficient of friction, wear and process parameters are examined. On this basis, a model for calculating the friction temperature is developed. / Die Konstruktion von Zugmitteln für kontinuierliche Fördereinheiten (z. B. Kunststoffketten) beruht bisher auf einer rein mechanischen Dimensionierung. Allerdings sind mechanische Grenzwerte zur Vermeidung von Systemausfall nur bedingt anwendbar. Bei größeren Geschwindigkeiten oder Druck erhöht sich insbesondere die thermische Beanspruchung, was bei einer bestimmten Temperatur zum Systemausfall durch Erweichung oder Schmelzen der Werkstoffe führt. In systematischen Untersuchungen wurden die Korrelationen zwischen Reibungstemperatur, Reibungskoeffizient, Verschleiß und den Prozessparametern untersucht. Auf dieser Basis wurde ein Modell zur Berechnung der Reibungstemperatur entwickelt.

La famille des élastomères silicones LSR (Liquid Silicone Rubber) de haute technicité est identifiée comme celle possédant les plus forts arguments de développement au cours des prochaines décennies en raison de leurs propriétés spécifiques et de leurs facilités de mise en forme en grande série. Notamment, le moulage par injection du LSR sur d’autres matières telles que les thermoplastiques ou les métaux est aujourd’hui possible, ce qui ouvre la possibilité d’obtenir des composants multi-matières, multi-couleurs et de nouvelles fonctionnalités. Cette thèse se concentre sur la transformation des élastomères silicones LSR dans le but de mieux appréhender les phénomènes impliqués, afin d’améliorer les procédés d’élaboration et d’optimiser les conditions de transformation des composants élastométriques mono ou bi-matières à géométrie et propriété fonctionnelle bien définie. Les comportements rhéologique, cinétique et thermique des élastomères silicones ont été étudiés et caractérisés sous des conditions réelles de mise en œuvre par différentes méthodes associées. Un modèle thermo-rhéo-cinétique a été développé et ensuite implémenté dans un code de calcul de remplissage Cadmould® pour simuler le moulage par injection des élastomères silicones LSR ou encore le surmoulage de thermoplastiques. Pour la validation des modèles choisis et des paramètres identifiés, les essais d’injection sur l’outillage industrielle instrumenté ont été réalisés et confrontés à des résultats numériques obtenus. Enfin, la caractérisation de l’adhésion et l’adhérence interfaciale entre les thermoplastiques et les élastomères silicones a été réalisé sous différentes sollicitations complexes. De plus, l’évolution d’adhérence interfaciale des assemblages collés au cours de la vulcanisation des élastomères silicones a été caractérisée par l’essai de traction en utilisant un rhéomètre rotatif sous différentes modes de chauffage. / The family of high technology silicone elastomers LSR (Liquid Silicone Rubber) is identified as having the strongest arguments for development in the coming decades due to their unique properties and easy forming in large series. In particular, the injection molding of LSR on other materials such as thermoplastics or metals is possible today, which opens the possibility of obtaining multi-material, multi-color and new features components. The work presented in this thesis focuses on the transformation of silicone elastomers in order to better understand the phenomena involved, as to improve production processes and optimize processing conditions for mono or bi-material components in geometry and property functional well defined. The rheological, curing kinetic and thermal behaviors of silicone elastomers have been studied and characterized under real conditions of production by different methods combined. A thermo-rheo-kinetic model was then developed and implemented in commercial computer software Cadmould® to simulate the injection molding process of LSR or the overmolding process of LSR on to thermoplastics. For the validation of the models chosen and the parameters identified, the injection molding tests on industrial instrumented tools were performed and compared to numerical results. Finally, the characterization of interfacial adhesion between the thermoplastic and silicone elastomers was carried out under various adhesion tests. Moreover, the evolution of interfacial adhesion in thermoplastic/silicone components during the vulcanization of silicone elastomers has been characterized by the tensile test using a rotating rheometer in different heating cycles

Due to the rising demand of light-weight constructions as well as the conservation of resources, the density and weight of thermoplastic parts could be influenced significantly by using the thermoplastic foam injection molding process. The structure of the foam injection molded part, which typically means solid surface layers and a cellular core, usually results in a weight saving. Furthermore the materials structure leads to an increasing of the specific bending stiffness with a simultaneous low tendency to warp. The present study was aimed to analyze the interactions between microcellular structure, joining process and the resulting mechanical properties of the molded part. Therefore, the microcellular injection molding process (MuCell®) as well as the vibration welding were used. Whereas the established welding processes for solid injection molded parts have already achieved a high degree of perfection within the last decades, the joining of microcellular thermoplastics entails several specific characteristics, because the injection foaming process highly influences the basic material properties. In contrast to solid materials, the weld seam properties after joining are mainly affected by the design constraints of the microcellular structure.

The training of movement procedures to increase the skills of athletes is a fundamental part of competitive sports. A realistic training, supported by technical equipment provides athletes a better success of training and is requested by trainers and training centers all over the world. Especially in winter sports, like luge or bob, a realistic training simulation is not always possible and demands adaptations of specific training procedures. As a part of this article, a new multilayer slide-foil will be presented, which allows athletes an even more realistic training. For this purpose the structure and production process of the foil composite will be shown, as well as results of the tribological behaviour of the foil. / Das Training von Bewegungsabläufen, zur Steigerung von Fähigkeiten, ist ein fundamentaler Bestandteil im Leistungssport. Ein realistisches Training, unterstützt durch technische Systeme, ermöglicht es Athleten optimale Trainingserfolge zu erzielen und wird dementsprechend von Trainern und Leistungszentren überall auf der Welt gewünscht. Insbesondere in Wintersportarten, wie z. B. Rennrodeln oder Bobfahren, kann dies allerdings nur bedingt realisiert werden und erfordert oftmals Abstriche bei der Trainingsgestaltung. Im Rahmen dieses Beitrags wird daher eine mehrschichtige Verbundfolie vorgestellt, welche den Athleten ein realistischeres Training ermöglichen soll. Hierzu werden zum einen der Aufbau und die Herstellung des Folienverbundes erläutert sowie tribologische Untersuchungsergebnisse präsentiert.

A variety of analytical and numerical approaches for calculating the friction temperature have been developed in the past. However, none is capable to estimate the friction temperature of thermoplastic friction pairings. Therefore, a semi-analytical model for predicting the friction temperature has been developed. Dry friction and periodically recurring contact is a premise. In the article the derivation is shown und influencing parameters are explained. A validation is made by experimental studies on a conveyor system. The model can be applied to sliding chain conveyor as well as perspectively similar tribological systems.

L'industrie de la fibre de carbone connaît actuellement une forte croissance, passant d'une demande annuelle mondiale de 18 000 tonnes en 2001 à 48 000 tonnes en 2013. Entre l'important gisement de déchets composites à valoriser et les différentes mesures législatives françaises et européennes prises en faveur d'une gestion durable des déchets, le recyclage des composites carbone (PRFC - Polymères Renforcés de Fibres de Carbone) offre d'intéressantes perspectives environnementales et économiques. L'objectif de ce travail de thèse est d'obtenir des composites thermoplastiques à partir de fibres de carbone recyclées. Des fibres de carbone ont ainsi été récupérées du traitement par vapo-thermolyse de composites à matrice époxyde fabriqués par LRI (Liquid Resin Infusion). La vapo-thermolyse est un procédé thermochimique utilisant la vapeur d'eau surchauffée à pression atmosphérique pour la dégradation de la matrice organique des composites et la récupération des fibres de carbone. De prime abord, l'étude des propriétés des fibres montre que le procédé est particulièrement efficace pour dégrader la résine tout en préservant les propriétés mécaniques des fibres récupérées. Deux voies de formulation sont alors proposées. La première concerne l'élaboration de granulés thermoplastiques pour l'injection ; la seconde l'élaboration de mats à orientation aléatoire pour la fabrication de TRE (Thermoplastique Renforcé Emboutissable). L'étude des propriétés mécaniques des composites ainsi élaborés montre des résultats comparables à ceux obtenus pour des matériaux élaborés à partir de fibres vierges. La fibre de carbone recyclée par vapo-thermolyse constitue donc une fibre compétitive en tant que renfort pour des composites thermoplastiques à fibres courtes. / World need in carbon fibre grew from 18,000 tons per year in 2001 to 48,000 tons in 2013. With the increasing amount of composite waste and the recent French or European legislation focus towards a sustainable waste management, carbon fibre composites recycling offers interesting economic and environmental perspectives. This project aims at enabling the manufacturing of thermoplastic composites from recycled carbon fibres. To reach this goal, PAN-based carbon fibres were recycled from epoxy resin/carbon fibre composites by steam-thermolysis. It is a thermochemical process using superheated steam at environmental pressure to degrade the organic matrix of composites and thus to recover carbon fibres. Reclaimed carbon fibres were first studied so as to show that the steam-thermal process is particularly efficient to degrade the epoxy resin of composites while maintaining fibres mechanical properties. Two kinds of composites were then considered: short-fibre reinforced compounds for injection and randomly-oriented fibre mat reinforced thermoplastics. Their mechanical properties were studied and results show that mechanical performances of recycled carbon fibre-based composites are similar to those of virgin carbon fibre-based composites. Steam-thermolysis recycled carbon fibre is a competitive fibre while being used as reinforcement for short fibre reinforced thermoplastics.