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Title: Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process

Abstract

We report carbon fiber reinforced composites have received growing attention because of their superior performance and high potential for lightweight systems. An economic method to manufacture the parts made of these composites is a sequence of forming followed by a compression molding. The first step in this sequence is called preforming that forms the prepreg, which is the fabric impregnated with the uncured resin, to the product geometry, while the molding process cures the resin. Slip between different prepreg layers is observed in the preforming step, and it is believed to have a non-negligible impact on the resulting geometry. This paper reports a method to characterize the interaction between different prepreg layers, which should be valuable for future predictive modeling and design optimization. An experimental device was built to evaluate the interactions with respect to various industrial production conditions. The experimental results were analyzed for an in-depth understanding about how temperature, relative sliding speed, and fiber orientation affect the tangential interaction between two prepreg layers. Moreover, a hydro-lubricant model was introduced to study the relative motion mechanism of this fabric-resin-fabric system, and the results agreed well with the experiment data. Lastly, the interaction factors obtained from this research will bemore » implemented in a preforming process finite element simulation model.« less

Authors:
 [1];  [2];  [1];  [1];  [1];  [3];  [3];  [4];  [1]
  1. Northwestern Univ., Evanston, IL (United States)
  2. Northwestern Univ., Evanston, IL (United States); Harbin Inst. of Technology (China)
  3. Ford Motor Company, Dearborn, MI (United States)
  4. Dow Chemical Company, Auburn Hills, MI (United States)
Publication Date:
Research Org.:
Ford Motor Company, Dearborn, MI (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
OSTI Identifier:
1504734
Grant/Contract Number:  
EE0006867
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Journal of Manufacturing Science and Engineering
Additional Journal Information:
Journal Volume: 140; Journal Issue: 8; Journal ID: ISSN 1087-1357
Publisher:
ASME
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 36 MATERIALS SCIENCE; 97 MATHEMATICS AND COMPUTING

Citation Formats

Zhang, Weizhao, Ma, Xuan, Lu, Jie, Zhang, Zixuan, Jane Wang, Q., Su, Xuming, Zeng, Danielle, Mirdamadi, Mansour, and Cao, Jian. Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process. United States: N. p., 2018. Web. doi:10.1115/1.4039979.
Zhang, Weizhao, Ma, Xuan, Lu, Jie, Zhang, Zixuan, Jane Wang, Q., Su, Xuming, Zeng, Danielle, Mirdamadi, Mansour, & Cao, Jian. Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process. United States. doi:10.1115/1.4039979.
Zhang, Weizhao, Ma, Xuan, Lu, Jie, Zhang, Zixuan, Jane Wang, Q., Su, Xuming, Zeng, Danielle, Mirdamadi, Mansour, and Cao, Jian. Mon . "Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process". United States. doi:10.1115/1.4039979. https://www.osti.gov/servlets/purl/1504734.
@article{osti_1504734,
title = {Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process},
author = {Zhang, Weizhao and Ma, Xuan and Lu, Jie and Zhang, Zixuan and Jane Wang, Q. and Su, Xuming and Zeng, Danielle and Mirdamadi, Mansour and Cao, Jian},
abstractNote = {We report carbon fiber reinforced composites have received growing attention because of their superior performance and high potential for lightweight systems. An economic method to manufacture the parts made of these composites is a sequence of forming followed by a compression molding. The first step in this sequence is called preforming that forms the prepreg, which is the fabric impregnated with the uncured resin, to the product geometry, while the molding process cures the resin. Slip between different prepreg layers is observed in the preforming step, and it is believed to have a non-negligible impact on the resulting geometry. This paper reports a method to characterize the interaction between different prepreg layers, which should be valuable for future predictive modeling and design optimization. An experimental device was built to evaluate the interactions with respect to various industrial production conditions. The experimental results were analyzed for an in-depth understanding about how temperature, relative sliding speed, and fiber orientation affect the tangential interaction between two prepreg layers. Moreover, a hydro-lubricant model was introduced to study the relative motion mechanism of this fabric-resin-fabric system, and the results agreed well with the experiment data. Lastly, the interaction factors obtained from this research will be implemented in a preforming process finite element simulation model.},
doi = {10.1115/1.4039979},
journal = {Journal of Manufacturing Science and Engineering},
issn = {1087-1357},
number = 8,
volume = 140,
place = {United States},
year = {2018},
month = {5}
}

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