The document discusses various fiber reinforced plastic (FRP) composite manufacturing processes. It defines FRP composites and describes common matrix materials like thermoset and thermoplastic resins. Manufacturing methods covered include hand lay-up, spray-up, resin transfer molding (RTM), filament winding, pultrusion, reaction injection molding (RIM), and matched-die molding. Each process is explained along with associated materials, equipment, advantages, disadvantages and applications.
My presentation on resin transfer molding. Not much description included. For reference i would recommend
" Composite manufacturing by Sanjay Mazumdar".
RTM is a low-pressure molding process, where a mixed resin and catalyst are injected into a closed mold containing a fiber pack or preform . when the resin has cured the mold can be opened and finished component removed.
My presentation on resin transfer molding. Not much description included. For reference i would recommend
" Composite manufacturing by Sanjay Mazumdar".
RTM is a low-pressure molding process, where a mixed resin and catalyst are injected into a closed mold containing a fiber pack or preform . when the resin has cured the mold can be opened and finished component removed.
Fibre Reinforced Plastic manufacturing methodsjeff jose
Composites manufacturing processes are complex, and involve combinations of the following physical processes:
1) Reinforcement Shaping
2) Resin Infusion
3) Composite Consolidation
Advantages and disadvantages of processing techniques
plastic composite manufacturing
Hand Lay-up
Spray up method
Filament winding
Match die molding
Pultrusion
Resin transfer molding
Reaction injection molding
Hand Lay-Up is well suited for low volume production of product.
This method can be used for both corrosion barrier and the structural portion
Fiber is chopped in a hand-held gun and fed into a spray of catalyzed resin directed at the mold. The deposited materials are left to cure under standard atmospheric conditions.
Series of powerpoint slides showing 6 different composite forming techniques: Hand lay-up, vacuum bagging, compression moulding, filament winding, pultrusion and resin transfer moulding. The slides are adapted from the University of Liverpool "Composite Materials" lectures [MATS311] by Prof. W. Cantwell.
Autoclave is a closed vessel (Round or Cylindrical) in which processes occur under simultaneous application of high temperature and pressure. Autoclave molding technique is similar to vacuum bag and pressure bag molding method with some modifications. This method employs an autoclave to provide heat and pressure to the composite product during curing.
Fibre Reinforced Plastic manufacturing methodsjeff jose
Composites manufacturing processes are complex, and involve combinations of the following physical processes:
1) Reinforcement Shaping
2) Resin Infusion
3) Composite Consolidation
Advantages and disadvantages of processing techniques
plastic composite manufacturing
Hand Lay-up
Spray up method
Filament winding
Match die molding
Pultrusion
Resin transfer molding
Reaction injection molding
Hand Lay-Up is well suited for low volume production of product.
This method can be used for both corrosion barrier and the structural portion
Fiber is chopped in a hand-held gun and fed into a spray of catalyzed resin directed at the mold. The deposited materials are left to cure under standard atmospheric conditions.
Series of powerpoint slides showing 6 different composite forming techniques: Hand lay-up, vacuum bagging, compression moulding, filament winding, pultrusion and resin transfer moulding. The slides are adapted from the University of Liverpool "Composite Materials" lectures [MATS311] by Prof. W. Cantwell.
Autoclave is a closed vessel (Round or Cylindrical) in which processes occur under simultaneous application of high temperature and pressure. Autoclave molding technique is similar to vacuum bag and pressure bag molding method with some modifications. This method employs an autoclave to provide heat and pressure to the composite product during curing.
Fabrication of Pneumatic Compression Molding Machine for FRP CompositesIRJET Journal
https://irjet.net/archives/V4/i7/IRJET-V4I728.pdf
Similar to y9he9rkhtvclqvgomnwm-signature-ae447a85cdf7452ab40b675cbe02036c11a196a1d748943bd6bb5b48496f4260-poli-141116104322-conversion-gate02.pdf (20)
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We have compiled the most important slides from each speaker's presentation. This year’s compilation, available for free, captures the key insights and contributions shared during the DfMAy 2024 conference.
Water billing management system project report.pdfKamal Acharya
Our project entitled “Water Billing Management System” aims is to generate Water bill with all the charges and penalty. Manual system that is employed is extremely laborious and quite inadequate. It only makes the process more difficult and hard.
The aim of our project is to develop a system that is meant to partially computerize the work performed in the Water Board like generating monthly Water bill, record of consuming unit of water, store record of the customer and previous unpaid record.
We used HTML/PHP as front end and MYSQL as back end for developing our project. HTML is primarily a visual design environment. We can create a android application by designing the form and that make up the user interface. Adding android application code to the form and the objects such as buttons and text boxes on them and adding any required support code in additional modular.
MySQL is free open source database that facilitates the effective management of the databases by connecting them to the software. It is a stable ,reliable and the powerful solution with the advanced features and advantages which are as follows: Data Security.MySQL is free open source database that facilitates the effective management of the databases by connecting them to the software.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
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Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
2. DEFINITION
Fiber Reinforced Polymer (FRP)
Composites are defined as:
“A matrix of polymeric material that is
reinforced by fibers or other
reinforcing material”
3. Processes
• Matched die molding
• RTM
• Spray-up
• Hand lay-up
• Filament winding
• Pultrusion
• RIM
4. Benefits Of FRP
• HIGH STRENGTH/WEIGHT RATIO
• ORIENTATED STRENGTH
• DESIGN FLEXIBILITY
• LIGHTWEIGHT
• CORROSION RESISTANCE
• LOW MAINTENANCE/LONG-TERM DURABILITY
• LARGE PART SIZE POSSIBLE
• TAILORED AESTHETIC APPEARANCE
• DIMENSIONAL STABILITY
• LOW THERMAL CONDUCTIVITY
• LOW INSTALLED COSTS
6. MATERIALS: RESINS
• PRIMARY FUNCTION:
“TO TRANSFER STRESS BETWEEN
REINFORCING FIBERS AND TO PROTECT
THEM FROM MECHANICAL AND
ENVIRONMENTAL DAMAGE”
• TYPES:
– THERMOSET
– THERMOPLASTIC
8. Matrix Materials – FRP
• Intermediate length fiber reinforcement
– The longer the fibers, the more difficult it is to coat the fibers
enough to reap strength benefits
– Low viscosity thermosets “wet-out” the materials better than high
viscosity thermoplastics
– Generally use unsaturated polyester and vinylester resins for
FRP
• Very long fibers or continuous fibers
– Typically used with thermosets, also for “wet-out” reasons
– Used generally in advanced composite parts and have greater
material property requirements
– Generally use epoxy resins
9. Reinforcements
• Three main types of fibers
– Fiberglass
– Carbon fiber or Graphite
– Organic fibers, aramids (kevlar)
10. • Hand lay-up technique is the simplest method of
composite processing.
• The processing steps are quite simple
First of all, mould is treated with a release agent-
to prevent sticking
Gel coat layers are placed on the mold- to give
decorative and protective surface
Put the reinforcement (woven rovings or
chopped strand mat)
11. The thermosetting resin is mixed with a curing
agent, and applied with brush or roller on the
reinforcement
Curing at room temperature. After curing either
at room temperature or at some specific
temperature, mold is opened and the developed
composite part is taken out and further
processed.
Hand lay-up method finds application in many
areas like aircraft components, automotive parts,
boat hulls, diase board, deck etc.
13. Materials used
Matrix Epoxy, polyester, polyvinyl ester, phenolic
resin, unsaturated polyester, polyurethane
resin
Reinforcemen
t
Glass fiber, carbon fiber, aramid fiber,
natural plant fibers (sisal, banana, nettle,
hemp, flax etc.)
(all these fibers are in the form of
unidirectional mat, bidirectional (woven)
mat, stitched into a fabric form, mat of
randomly oriented fibers)
Raw materials used in hand lay-up method
14. Variation of hand lay-up
Mould is treated with a release agent-to prevent sticking
Gel coat layers are placed on the mold- to give
decorative and protective surface
The gun sprays the mixture of chopped fiber, resin &
catalyst on to a mould
Rolled out to remove entrapped air & give a smooth
surface
Poor roll out can induce structural weakness by leaving
air bubbles, dislocation of fibers and poor wet out
• Spray lay-up method is used for lower load carrying
parts like small boats, bath tubs, fairing of trucks etc
16. Materials used
Matrix Epoxy, polyester, polyvinyl ester, phenolic
resin, unsaturated polyester, polyurethane
resin
Reinforcement Glass fiber, carbon fiber, aramid fiber,
natural plant fibers (sisal, banana, nettle,
hemp, flax, coir, cotton, jute etc.)
(all these fibers are in the form of
chopped short fibers, flakes, particle fillers
etc.)
Raw materials used in spray up method
18. Typical Preform Fiber Weaves
Polyester resins
Epoxy resins
Phenolic resins and other thermo set resins
Type of material for which process is used
19. RTM PROCESS
• impregnating preformed dry reinforcement in a
closed mold with wet thermosetting resin under
pressure
• production rate comparison
– 2 - 8 pph (parts per hour)
– spray-up @ 0.5 pph
– SMC, injection molding @ 30 pph (chopped fibers,
high pressures requires >>$ tooling)
21. RTM EQUIPMENT
• resin/curing agent (catalyst) mixing equipment
– positive displacement piston pumping cycle
– maintain accurate ratio control between resin and curing
agent
– RTM process requires low injection pressures (30 psi - 100
psi)
– piston type positive displacement pumps are critical due to
changing back pressure conditions - as resin is pushed
through reinforcement an increasing back pressure builds
against metering pumps - if slippage occurs at pump,
resin/curing agent ratio will be affected
• with resin system components accurately metered,
sent through flexible hoses to a mix head
22. MOLD DESIGN
• gasket around perimeter
• inlet injection port
– located at the lowest point of mold
– plug or check valve incorporated
• vent ports located at highest point of mold
• for high volume, tightly toleranced parts may use
press - controls parallelism of mold set during
opening and closing and holds mold closed
during injection (alternative is manually clamping
or fastening)
23. RTM PROCESS
• may or may not take place under vacuum (assists in
minimizing air entrapment)
• mixer/injection head is inserted into mold
• injection pressure pushes check valve off its seat and
allows resin to begin filling
• air is pushed ahead of resin
• resin will begin flowing from vent ports
– if part design is simple may be full
– if part design complex, may require slight overfill to vent all
air
• vent ports are pinched off and internal pressure
causes inlet check valve to close
24. RTM PROCESS ISSUES
• critical to control infusion rate and flow front of
resin so that it infiltrates fiber preform evenly and
completely, but quickly before gelling
• resin is injected in center of part to guard against
formation of air pockets and minimize distance
resin must travel
• care must be exercised to insure reinforcement
does not move during injection (fiber wash)
25. ADVANTAGES DISADVANTAGES
- -
Faster Production
Labor Savings
Dimensional Tolerances
Surface Finish
Lower Material Wastage
Very large and complex shapes can
made efficiently
Greater Tooling Design and
Construction Skills Required
Higher Tool Cost
Reinforcement loading may
be difficult with complex parts
Mold design is complex
27. 27
FILAMENT WINDING
shaft
Filament Winding (one-step process)
-very high rate process
-Amenable to automated machine control
(little labor required)
-pressure bottle and cylindrical shapes
-rapidly growing variety applications
-continuous roving/yarns/strands
-Continuous filaments wound a mandrel(tool)
Major concerns in filament windings
-Resin selection
-Viscosity
-Need diluent or heat to lower viscosity
-Curing requirements
Fiber Requirements
-high tensile strength
-highest mechanical quality
-finishes to improve handling
28. REINFORCEMENTS RESINS
fiber in roving form
E-glass, S-glass
carbon/graphite
aramid
hybrids (within layer and
layer to layer)
wet or prepreg
epoxy
vinyl ester
polyester
Epoxy resins
Polyester resins
Phenolic resins
Silicone resins
29. 29
Filament Windings
Impregnation methods
-Wet winding
-Fiber is impregnated immediately
-Most common in aerospace
-Most economical
Prepreg winding
- resin and fiber
combined in separate step
-better control
-better wet-out
-allows use of resin with
viscosities too high for wet
winding
Wind fibers are n two ways:
-planar winding: side by side no
cross over
-Helical winding: mandrel
30. Filament Windings
Mandrel: can be in sections (removed piece by piece) can be salt or
sand (dissolved)
-after winding, product is cured on mandrel with heat alone (under
tension)
-tension can affect void content, resin content, thickness or part.
32. 32
Filament Windings
Characteristics of filament winding
-automation
-no prepreg step
-low labor cost
-high machine cost
Tape winding
-similar to filament winding except uses prepreg tape
-Wrapped around mandrel using rolling machine
-Used for golf clubs/pipes/tubes/fishing rods
33. ADVANTAGES DISADVANTAGES
-highly reproducible nature of the process
(layer to layer, part to part)
-continuous fiber over the entire part
high fiber volume is obtainable
-ability to orient fibers in the load direction
-fiber and resin used in lowest cost form
-autoclave not necessary
-a very fast and economic method
-Lack of ductility
-Low modulus of elasticity
-part configuration must facilitate mandrel
extraction (no trapped tooling)
-mandrel could be complex and expensive
-inability to wind reverse curvature
-inability to easily change fiber path within
one layer
-as wound external surface may not be
satisfactory for some applications
34. FILAMENT WINDING
APPLICATIONS
• surfaces of revolution
– cylinders, pipe or tubing
– spherical or conical
– pressure
• Storage tank
• Railway tank car
• Pipe
• Aerospace
35. Pultrusion
Pultrusion: a process for producing continuous length of shapes with a
constant cross section by pulling resin-impregnated fibers through a
heated die where curing occurs.
Characteristics
-Pultrusion produces parts with
-high fiber volume, high percentage of unidirectional
reinforcement.
-primarily a method for thermosetting resins
-one of few continuous FRP process
-Accounts for 3% of total FRP
-based on continuous fibers
36. 36
Pultrusion
Process Steps:
-String-up of desired fiber pattern
-Resin impregnation
-Preforming shape around mandrel (if necessary)
-Pre-heat (augmented cure)
-Cut finished part to length
-Speed: 0.5 to 10 ft/min
-Throughput: up to 4 lb/min
39. ADVANTAGES DISADVANTAGES
continuous process
-easy to automate, low labor
-High output; very long parts are
possible
-Uses inexpensive forms of
reinforcement
-Selective placement of reinforcement
relatively easy
-Low scrap
-Cross-sections must generally be
uniform
-difficult to maintain tight tolerances
-quick curing resin systems typically
have lower mechanical properties
-complexity of process
40. APPLICATIONS OF PULTRUSION
• Truck & bus components, such as body panels
and drive shaft
• Construction members such as building panels,
window & door frames, beams,pipes,cable trays
etc.
• Electrical equipment such as ladders,booms for
cherry picker trucks,tool handles etc.
• Sporting goods such as ski poles & fishing rods
41. Moulding Methods
Matched-die moulding
-The composite material is pressed between
heated matched dies
-Pressure required depends on the flow
characteristics of the feed materials
- The feed materials flows into the contours of the
mould and cures at high temp.
42. • Matched die or Compression molding
– Reduced flow path over injection or extrusion
– SMC compression molding allows for continuous
fibers, mats or weaves
– These processes offer parts that are finished on both
sides where most other composite processes do not
43.
44. REACTION INJECTION MOULDING
RIM utilizes highly reactive two-component resins that are low-viscosity
liquids at room temperature
To initiate mixing and injection,the piston in the mixhead moves up and the
two resin components collide in the mixing chamber under high speed and
high pressure
The resin streams collide at 100-200m/s resulting in pressures of 10-40MPa
Following mold filling, the piston purges the mixhead of remaining resin
Since crosslinking is initiated by mixing and is very rapid,the resin gels
within seconds after the mold has been filled,paertially aided by heating of
the mould
To ensure complete crosslinking,it is important that exactly correct
proportions of resin components are mixed
46. REINFORCED REACTION
INJECTION MOLDING
• Reinforced Reaction Injection Molding (RRIM) is
a process used to produce polyurethane and
polyurea thermoset polymers
• In RRIM short fibers are added to one of the
resin components prior to final resin mixing
• It has proved difficult to include fibers longer
than 0.5mm, since this leads to a too high
viscosity
47. • Although even such short fibers provide
significantly increased stiffness, damage
tolerance, dimensional tolerance and lower CTE
over what RIM components may offer, articles
produced through RRIM nevertheless have poor
structural properties from a composite view point
• This process is mainly used in automative
industry, where short cycle times and low labour
cost is important
48. STRUCTURAL REACTION
INJECTION MOLDING
• A subset of RIM is structural reaction injection molding (SRIM), which
uses fiber meshes for the reinforcing agent. The fiber mesh is arranged
in the mold and the polymer mixture is injection molded over it
• SRIM is the result of conceptually combining RTM and RIM
• In SRIM the reinforcement is first placed in the mold and following
mold closure the highly impingement-mixed resin is injected into the
mold to impregnate the reinforcement
• SRIM is used for long series where the significantly higher initial cost
for injection equipment may be written off
49. ADVANTAGES/DISADVANTAGE
S OF RIM PROCESS
– RIM resin builds viscosity rapidly (higher average viscosity during
mold filling)
• applications must be simple geometries
• SRIM preform must be less complex and lower in reinforcement
content
• parts do not normally flash out of mold parting line sufficiently to
require sealing beyond metal land area or a pinch off around
perimeter of part (low viscosity of RTM resin requires gasket or o-
ring)
– highly reactive nature of RIM resin systems leads to cycle times
currently faster than achieved with RTM process
– mix ratios of RIM resin systems nearly 1:1 in volume
• ideally suited to impingement mixing process
• self-cleaning mix element
• RTM ratios (as high as 100:1 by volume) require mixing in a static
mixer and subsequent solvent flush