Thesis (MEng)--Stellenbosch University, 2015. / ENGLISH ABSTRACT: The South African manufacturing industry plays a pivotal role in the growth of its local economy. Modern manufacturing requirements include the ability to respond quickly to product variability, fluctuations in product demand and new process technologies. The reconfigurable manufacturing paradigm has been proposed to meet the demands of the new manufacturing requirements. In order to assess the feasibility of incorporating automated, reconfigurable manufacturing technologies into the production process of thermoplastic fibre-reinforced composite parts, a system, based on the thermoforming process, that implements these technologies was developed and evaluated. The assessment uses a seat pan for commercial aircraft as case study. Aspects that were addressed include the architecture, configuration and control of the system. The architecture and configuration addressed the sheet cutting, fixturing, reinforcing, heating, forming, quality assurance and transportation. The control, implemented using agents and based on the ADACOR holonic reference architecture, addresses the cell control requirements of the thermoforming process. An evaluation of the system’s reconfigurability and throughput is performed using KUKA Sim Pro. The evaluation of the system’s throughput is compared to the predicted throughput of the conventional technique for manufacturing thermoplastic fibre reinforced composite parts in a thermoforming process. The evaluation of the system’s performance show that the system designed in this thesis for the manufacture of a thermoplastic fibre-reinforced composite seat pan sports a significant advantage in terms of throughput rate, which demonstrates its technical feasibility. The evaluation of the system’s reconfigurability show that, through its ability to handle new hardware and product changes, it exhibits the reconfigurability characteristics of modularity, convertibility, integrability and scalability. / AFRIKAANSE OPSOMMING: Die Suid-Afrikaanse vervaardigingsbedryf speel 'n sentrale rol in die groei van die plaaslike ekonomie. Moderne vervaardiging vereistes sluit in die vermoë om vinnig te reageer op die produk veranderlikheid, skommelinge in die produk aanvraag en nuwe proses tegnologieë. Die herkonfigureerbare vervaardiging paradigma is voorgestel om te voldoen aan die nuwe produksie vereistes. Ten einde die uitvoerbaarheid van die integrasie van outomatiese, herkonfigureerbare vervaardiging-tegnologieë in die produksieproses van veselversterkte saamgestelde onderdele te evalueer, is 'n stelsel, gebaseer op die termo-vormingsproses, wat sulke tegnologieë implementeer, ontwikkel. Die assessering gebruik 'n sitplek pan vir kommersiële vliegtuie as gevallestudie. Aspekte wat aangespreek is sluit in die argitektuur, konfigurasie en beheer van die vervaardigingstelsel. Die argitektuur en konfigurasie spreek aan die sny, setmate, versterking, verwarming, vorm, gehalteversekering en vervoer van n veselversterkte saamgestelde sitplek pan in 'n termo-vormingsproses. Die beheer, geïmplementeer deur die gebruik van agente en gebaseer op die ADACOR holoniese verwysing argitektuur, spreek die selbeheervereistes van die termo-vormingsproses aan. 'n Evaluering van die stelsel se herkonfigureerbaarheid en deurvoer word gedoen met die behulp van KUKA Sim Pro. Die evaluering van die stelsel se deurvoer word vergelyk met die deurvoer van die konvensionele vervaardigingsproses vir termoplastiese vessel-versterkte saamgestelde onderdele in 'n termo-vormingsproses. Die evaluering van die stelsel se prestasie toon dat die stelsel wat in hierdie tesis ontwerp is vir die vervaardiging van 'n termoplastiese vessel-versterkte saamgestelde sitplek pan, hou 'n beduidende voordeel, in terme van deurvloeikoers, in wat die stelsel se tegniese haalbaarheid toon. Die evaluering van die stelsel se herkonfigureerbaarheid wys dat, deur middel van sy vermoë om nuwe hardeware en produk veranderinge te hanteer, die stelsel herkonfigureerbare einskappe van modulariteit, inwisselbaarheid, integreerbaarheid en skaalbaarheid vertoon.

Carbon nanotubes have now been a subject of intense research for approaching two decades. Although a short time relative to most conventional materials, much hype about the intrinsic properties of this material has now been substantiated by experiment. The results are conclusive that carbon nanotubes are truly phenomenal materials with highly desirable mechanical, electrical and thermal properties. Furthermore, multiwall carbon nanotubes (MWNTs) have emerged as the most economically viable and abundant form of carbon nanotubes, and therefore the most likely candidate for application. The key materials engineering challenge remains in effectively transferring their properties to macro-scale materials in the form of composites. It is here that research merges with application. This dissertation has therefore been directed to focus on carbon nanotube composites in an applied sense. Here, the state of the art is reviewed, and experimental results of carefully selected composite systems, studied in detail for (1) mechanical, (2) electrical and (3) thermal properties, are presented and discussed. In terms of mechanical properties, the effects of MWNTs for augmentation of the tensile properties of PAN-based carbon fiber, and fatigue performance of poly(methyl methacrylate) are investigated and reported. In MWNT composite PAN-based carbon fiber, the formation of an ordered interphase layer sheathing the nanotubes was observed in fracture surfaces, which indicated a clear importance of their function to template the growth of carbon formation in the PAN-based matrix fiber. These structures open up a route to nano-scale tailorability of the crystallographic morphology of the composite fibers. Large improvements in fatigue performance were observed in MWNT/PMMA composites compared to MWNT/chopped carbon fiber composites, and attributed to the nanometer scale dimensions of the MWNTs enabling them to mitigate submicron damage such as polymer crazing. In terms of electrical and thermal properties, MWNT/epoxy composites were superior to MWNT/carbon black composites. Furthermore, extremely large improvements in the thermal conductivity of epoxy were observed for epoxy-infiltrated aligned MWNT arrays. The alignment of the MWNTs was shown to play a dominant role in enabling the improvement. Finally, these results, in concert with the literature are discussed in terms of the application of carbon nanotubes in engineering materials.

We develop homogenization schemes for the effective mechanical and acoustical properties of linear viscoelastic inclusion reinforced composites. Generic procedures are studied and proposed, starting from the statics and elastic materials, followed by viscoelastic behaviors and the quasi-static approximation, to end up with dynamic viscoelastic models. For elastic composites, our main contributions regard homogenization schemes for coated inclusion reinforced materials. An original two-level recursive procedure is proposed. At each level, a homogenization model suitable for two-phase composites with aligned reinforcements is required. That makes the procedure very generic. The latter is used as stand-alone (i.e. for three-phase composites) or to achieve the first step of a two-step approach for multiphase materials (e.g. composites with misaligned coated fibers). With the quasi-static approximation, i.e. when inertial effects are ignored, we generalize the generic two-step and two-level procedures to predict both time dependent and harmonic effective mechanical properties (storage and loss moduli) of linear viscoelastic multiphase composites. The static and quasi-static models however cannot account for attenuation of acoustic waves due to scattering by the inclusions. Effective acoustic properties (phase velocities, attenuation factors) of viscoelastic inclusion reinforced composites are addressed by dynamic schemes. We propose a generic framework for the development of such homogenization models. It generalizes and unifies within a single formulation several methods of the literature. An independent-scattering model is derived. The link between dynamic schemes in the long-wave region and static models is shown. Finally, these homogenization schemes are integrated in a finite element model based on a discontinuous Galerkin formulation of the Helmholtz equation to simulate acoustic problems involving viscoelastic composite materials.

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