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Experimental and Simulative Analysis of the Impregnation Mechanics of Endless Fiber Rovings

  • Unidirectional (UD) composites are the most competitive materials for the production of high-end structures. Their field of application spreads from the aerospace up to automotive and general industry sector. Typical examples of components made of unidirectional reinforced composite materials are rocket motor cases, drive shafts or pressure vessels for hydrogen storage. The filament winding technology, the pultrusion process and the tape placement are processes suitable for the manufacturing using UD semi-finished products. The demand for parts made of UD composites is constantly increasing over the last years. A key feature for the success of this technology is the improvement of the manufacturing procedure. Impregnation is one of the most important steps in the manufacturing process. During this step the dry continuous fibers are combined with the liquid matrix in order to create a fully impregnated semi-finished product. The properties of the impregnated roving have a major effect on the laminate quality, and the efficient processing of the liquid matrix has a big influence on the manufacturing costs. The present work is related to the development of a new method for the impregnation of carbon fiber rovings with thermoset resin. The developed impregnation unit consists of a sinusoidal cavity without any moving parts. The unit in combination with an automated resin mixing-dosing system allows complete wet-out of the fibers, precise calibration of the resin fraction, and stable processing conditions. The thesis focuses on the modeling of the impregnation process. Mathematical expressions for the fiber compaction, the gradual increase of the roving tension, the static pressure, the capillarity inside the filaments of the roving, and the fiber permeation are presented, discussed, and experimentally verified. These expressions were implemented in a modeling algorithm. The model takes into account all the relevant material and process parameters. An experimental set-up based on the filament winding process was used for the validation of the model. Trials under different conditions have been performed. The results proved that the model can accurately simulate the impregnation process. The good impregnation degree of the wound samples confirmed the efficiency of the developed impregnation unit. A techno economical analysis has proved that the developed system will result to the reduction of the manufacturing costs and to the increase of the productivity.

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Author:Angelos Miaris
URN (permanent link):urn:nbn:de:hbz:386-kluedo-47381
Serie (Series number):IVW-Schriftenreihe (102)
Publisher:Institut für Verbundwerkstoffe GmbH
Place of publication:Kaiserslautern
Advisor:Peter Mitschang
Document Type:Doctoral Thesis
Language of publication:English
Publication Date:2017/08/09
Year of Publication:2012
Publishing Institute:Technische Universität Kaiserslautern
Granting Institute:Technische Universität Kaiserslautern
Acceptance Date of the Thesis:2012/06/01
Date of the Publication (Server):2017/08/10
Faculties / Organisational entities:Fachbereich Maschinenbau und Verfahrenstechnik
DDC-Cassification:6 Technik, Medizin, angewandte Wissenschaften / 620 Ingenieurwissenschaften und Maschinenbau
Licence (German):Creative Commons 4.0 - Namensnennung, nicht kommerziell, keine Bearbeitung (CC BY-NC-ND 4.0)