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In the last decade, injection molding of long-fiber reinforced thermoplastics
(LFT) has been established as a low-cost, high volume technique for manufacturing
parts with complex shape without any post-treatment [1–3]. Applications
are mainly found in the automotive industry with a volume annually
growing by 10% to 15% [4].
While first applications were based on polyamide (PA6 and PA6.6), the market
share of glass fiber reinforced polypropylene (PP) is growing due to cost savings
and ease of processing. With the use of polypropylene, different processing
techniques such as gas-assisted injection molding [5] or injection compression
molding [6] have emerged in addition to injection molding [7, 8].
In order to overcome or justify higher materials costs when compared to short
fiber reinforced thermoplastics, the manufacturing techniques for LFT pellets
with fiber length greater than 10mm have evolved starting from pultrusion by
improving impregnation and throughput [9] or by direct addition of fiber strands
in the mold [10–12].
The benefit of long glass fiber reinforcement either in PP or PA is mainly due
to the enhanced resistance to fiber pull-out resulting in an increase in impact
properties and strength [13–19], even at low temperature levels [20]. Creep
and fatigue resistance are also substantially improved [21, 22].
The performance of fiber reinforced thermoplastics manufactured by injection
molding strongly depends on the flow-induced microstructure which is
driven by materials composition, processing conditions and part geometry.
The anisotropic microstructure is characterized by fiber fraction and dispersion,
fiber length and fiber orientation.
Facing the complexity of this processing technique, simulation becomes a precious
tool already in the concept phase for parts manufactured by injection
molding. Process simulation supports decisions with respect to choice of concepts
and materials. The part design is determined in terms of mold filling
including location of gates, vents and weld lines. Tool design requires the
determination of melt feeding, logistics and mold heating. Subsequently, performance
including prediction of shrinkage and warpage as well as structural
analysis is evaluated [23].
While simulation based on two-dimensional representation of three-dimensional
part geometry has been extensively used during the last two decades, the
complexity of the parts as well as the trend towards solid modelling in CAD
and CAE demands the step towards three-dimensional process simulation. The scope of this work is the prediction of flow-induced microstructure during
injection molding of long glass fiber reinforced polypropylene using threedimensional
process simulation. Modelling of the injection molding process in
three dimensions is supported experimentally by rheological characterization
in both shear and extensional flow and by two- and three-dimensional evaluation
of microstructure.
In chapter 2 the fundamentals of rheometry and rheology are presented with
respect to long fiber reinforced thermoplastics. The influence of parameters
on microstructure is described and approaches for modelling the state of microstructure
and its dynamics are discussed.
Chapter 3 introduces a rheometric technique allowing for rheological characterization
of polymer melts at processing conditions as encountered during
manufacturing. Using this rheometer, both shear and extensional viscosity of
long glass fiber reinforced polypropylene are measured with respect to composition
of materials, processing conditions and geometry of the cavity.
Chapter 4 contains the evaluation of microstructure of long glass fiber reinforced
polypropylene in terms of two-dimensional fiber orientation and its dependence
on materials parameters and processing condition. For the evaluation
of three-dimensional microstructure, a technique based on x-ray tomography
is introduced.
In chapter 5, modelling of microstructural dynamics is addressed. One-way
coupling of interactions between fluid and fibers is described macroscopically.
The flow behavior of fibers in the vicinity of cavity walls is evaluated experimentally.
From these observations, a model for treatment of fiber-wall interaction
with respect to numerical simulation is proposed.
Chapter 6 presents the application of three-dimensional simulation of the injection
molding process. Mold filling simulation is performed using a commercial
code while prediction of 3D fiber orientation is based on a proprietary module.
The rheological and thermal properties derived in chapter 3 are tested by
simulation of the experiments and comparison of predicted pressure and temperature
profile versus recorded results. The performance of fiber orientation
prediction is verified using analytical solutions of test examples from literature.
The capability of three-dimensional simulation is demonstrated based on the
simulation of mold filling and prediction of fiber orientation for an automotive
part.
Solid particle erosion is usually undesirable, as it leads to development of cracks and
holes, material removal and other degradation mechanisms that as final
consequence reduce the durability of the structure imposed to erosion. The main aim
of this study was to characterise the erosion behaviour of polymers and polymer
composites, to understand the nature and the mechanisms of the material removal
and to suggest modifications and protective strategies for the effective reduction of
the material removal due to erosion.
In polymers, the effects of morphology, mechanical-, thermomechanical, and fracture
mechanical- properties were discussed. It was established that there is no general
rule for high resistance to erosive wear. Because of the different erosive wear
mechanisms that can take place, wear resistance can be achieved by more than one
type of materials. Difficulties with materials optimisation for wear reduction arise from
the fact that a material can show different behaviour depending on the impact angle
and the experimental conditions. Effects of polymer modification through mixing or
blending with elastomers and inclusion of nanoparticles were also discussed.
Toughness modification of epoxy resin with hygrothermally decomposed polyesterurethane
can be favourable for the erosion resistance. This type of modification
changes also the crosslinking characteristics of the modified EP and it was
established the crosslink density along with fracture energy are decisive parameters
for the erosion response. Melt blending of thermoplastic polymers with functionalised
rubbers on the other hand, can also have a positive influence whereas inclusion of
nanoparticles deteriorate the erosion resistance at low oblique impact angles (30°).
The effects of fibre length, orientation, fibre/matrix adhesion, stacking sequence,
number, position and existence of interleaves were studied in polymer composites.
Linear and inverse rules of mixture were applied in order to predict the erosion rate of
a composite system as a function of the erosion rate of its constituents and their
relative content. Best results were generally delivered with the inverse rule of mixture
approach.
A semi-empirical model, proposed to describe the property degradation and damage
growth characteristics and to predict residual properties after single impact, was
applied for the case of solid particle erosion. Theoretical predictions and experimental
results were in very good agreement.
Strahlerosionsverschleiß (Erosion) entsteht beim Auftreffen von festen Partikel
auf Oberflächen und zeichnet sich üblicherweise durch einen Materialabtrag aus, der
neben der Partikelgeschwindigkeit und dem Auftreffwinkel stark vom jeweiligen
Werkstoff abhängt. In den letzten Jahren ist die Anwendung von Polymeren und
Verbundwerkstoffen anstelle der traditionellen Materialien stark angestiegen.
Polymere und Polymer-Verbundwerkstoffe weisen eine relativ hohe Erosionsrate
(ER) auf, was die potenzielle Anwendung dieser Werkstoffe unter erosiven
Umgebungsbedingungen erheblich einschränkt.
Untersuchungen des Erosionsverhaltens anhand ausgewählter Polymere und
Polymer-Verbundwerkstoffe haben gezeigt, dass diese Systeme unterschiedlichen
Verschleißmechnismen folgen, die sehr komplex sind und nicht nur von einer
Werkstoffeigenschaft beeinflusst werden. Anhand der ER kann das
Erosionsverhalten grob in zwei Kategorien eingeteilt werden: sprödes und duktiles
Erosionsverhalten. Das spröde Erosionsverhalten zeigt eine maximale ER bei 90°,
während das Maximum bei dem duktilen Verhalten bei 30° liegt. Ob ein Material das
eine oder das andere Erosionsverhalten aufweist, ist nicht nur von seinen
Eigenschaften, sondern auch von den jeweiligen Prüfparametern abhängig.
Das Ziel dieser Forschungsarbeit war, das grundsätzliche Verhalten von
Polymeren und Verbundwerkstoffen unter dem Einfluss von Erosion zu
charakterisieren, die verschiedenen Verschleißmechanismen zu erkennen und die
maßgeblichen Materialeigenschaften und Kennwerte zu erfassen, um Anwendungen
dieser Werkstoffe unter Erosionsbedingungen zu ermöglichen bzw. zu verbessern.
An einer exemplarischen Auswahl von Polymeren, Elastomeren, modifizierten Polymeren und Faserverbundwerkstoffen wurden die wesentlichen Einflussfaktoren
für die Erosion experimentell bestimmt.
Thermoplastische Polymere und thermoplastische- und vernetzte- Elastomere
Die Versuche, den Erosionswiderstand ausgewählter Polymere (Polyethylene
und Polyurethane) mit verschiedenen Materialeigenschaften zu korrelieren, haben
gezeigt, dass es weder eine klare Abhängigkeit von einzelnen Kenngrößen noch von
Eigenschaftskombinationen gibt. Möglicherweise führt die Bestimmung der
Materialeigenschaften unter den gleichen experimentellen Bedingungen wie bei den Erosionsversuchen zu einer besseren Korrelation zwischen ER und
Materialkenngröße.
Modifiziertes Epoxidharz
Am Beispiel eines modifizierten Epoxidharzes (EP) mit verschiedener
Vernetzungsdichte wurde eine Korrelation zwischen Erosionswiderstand und
Bruchenergie bzw. Erosionswiderstand und Vernetzungsdichte gefunden. Die
Modifizierung erfolgte mit verschiedenen Anteilen von einem hygrothermisch
abgebauten Polyurethan (HD-PUR). Der Zusammenhang zwischen ER und
Vernetzungsparametern steht im Einklang mit der Theorie der Kautschukelastizität.
Modifizierungseffizienz in Duromeren, Thermoplasten und Elastomeren
Des weiteren wurde der Einfluss von Modifizierungen von Polymeren und
Elastomeren untersucht. Mit dem obenerwähnten System (d.h. EP/HD-PUR) läßt sich
auch der Einfluss der Zähigkeitsmodifizierung des Epoxidharzes (EP) auf das
Erosionsverhalten untersuchen. Es wurde gezeigt, dass für HD-PUR Anteile von
mehr als 20 Gew.% diese Modifizierung einen positiven Einfluss auf die
Erosionsbeständigkeit hat. Durch Variation der HD-PUR-Anteile können für dieses
EP Materialeigenschaften, die zwischen den Eigenschaften eines üblichen
Duroplasten und eines weniger elastischen Gummis liegen, erzeugt werden.
Deswegen stellt der modifizierte EP-Harz ein sehr gutes Modellmaterial dar, um den
Einfluss der experimentellen Bedingungen zu studieren, und zu untersuchen, ob
verschiedene Erodenten zu gleichen Erosionsmechanismen führen. Der Übergang
vom duroplastischen zum zähen Verhalten wurde anhand von vier Erodenten
untersucht. Aus den Versuchen ergab sich, dass ein solcher Übergang auftritt, wenn
sehr feine, kantige Partikel (Korund) als Erodenten dienen. Die Partikelgröße und -form ist von entscheidender Bedeutung für die jeweiligen Verschleißmechanismen.
Die Effizienz neuartiger thermoplastischer Elastomere mit einer cokontinuierlichen
Phasenstruktur, bestehend aus thermoplastischem Polyester und
Gummi (funktionalisierter NBR und EPDM Kautschuk), wurde in Bezug auf die
Erosionsbeständigkeit untersucht. Große Anteile von funktionalisiertem Gummi (mehr
als 20 Gew.%) sind vorteilhaft für den Erosionswiderstand. Weiterhin wurde
untersucht, ob sich die herausragende Erosionsbeständigkeit von Polyurethan (PUR)
durch Zugabe von Nanosilikaten eventuell noch steigern läßt. Das Ergebnis war,
dass die Nanopartikel sich vor allem bei einem kleinen Verschleißwinkel (30°) negativ
auswirken. Die schwache Adhäsion zwischen Matrix und Partikeln erleichtert den
Beginn und das Wachsen von Rissen. Dies führt zu einem schnelleren
Materialabtrag von der Materialoberfläche.
Faserverbundwerkstoffe
Ferner wurden Faserverbundwerkstoffe (FVW) mit thermoplastischer und
duromerer Matrix auf ihr Verhalten bei Erosivverschleiß untersucht. Es war von
großem Interesse, den Einfluss von Faserlänge und -orientierung zu untersuchen.
Kurzfaserverstärkte Systeme haben einen besseren Erosionswiderstand als die
unidirektionalen (UD) Systeme. Die Rolle der Faserorientierung kann man nur in
Verbindung mit anderen Parametern, wie Matrixzähigkeit, Faseranteil oder Faser-
Matrix Haftung, berücksichtigen. Am Beispiel von GF/PP Verbunden weisen die
parallel zur Verstreckungsrichtung gestrahlten Systeme den geringsten Widerstand
auf. Andererseits findet bei einem GF/EP System die maximale ER in senkrechter
Richtung statt. Eine Verbesserung der Grenzflächenscherfestigkeit beeinflusst die
Erosionsverschleißrate nachhaltig. Wenn die Haftung der Grenzfläche ausreichend
ist, spielt die Erosionsrichtung eine unbedeutende Rolle für die ER. Weiterhin wurde
gezeigt, dass die Präsenz von zähen Zwischenschichten zu einer deutlichen
Verbesserung des Erosionswiderstands von CF/EP- Verbunden führt.
Eine weitere Aufgabenstellung war es, die Rolle des Faservolumenanteils zu
bestimmen. „Lineare, inverse und modifizierte Mischungsregeln“ wurden
angewendet, und es wurde festgestellt, dass die inversen Mischungsregeln besser
die ER in Abhängigkeit des Faservolumenanteils beschreiben können.
Im Anwendungsbereich von Faserverbundwerkstoffen ist nicht nur die Kenntnis
der ER, sondern auch die Kenntnis der Resteigenschaften erforderlich. Ein
halbempirisches Modell für die Vorhersage des Schlagenergieschwellwertes (Uo) für den Beginn der Festigkeitsabnahme und der Restzugfestigkeit nach einer
Schlagbelastung wurde bei der Untersuchung des Erosionsverschleißes
angewendet. Experimentelle Ergebnisse und theoretische Vorhersagen stimmten
nicht nur für duromere CF/EP-Verbundwerkstoffe, sondern auch für
Verbundwerkstoffe mit einer thermoplastischen Matrix (GF/PP) sehr gut überein.
We study high dimensional integration in the quantum model of computation. We develop quantum algorithms for integration of functions from Sobolev classes \(W^r_p [0,1]^d\) and analyze their convergence rates. We also prove lower bounds which show that the proposed algorithms are, in many cases, optimal within the setting of quantum computing. This extends recent results of Novak on integration of functions from Hölder classes.
Interactive graphics has been limited to simple direct illumination that commonly results in an artificial appearance. A more realistic appearance by simulating global illumination effects has been too costly to compute at interactive rates. In this paper we describe a new Monte Carlo-based global illumination algorithm. It achieves performance of up to 10 frames per second while arbitrary changes to the scene may be applied interactively. The performance is obtained through the effective use of a fast, distributed ray-tracing engine as well as a new interleaved sampling technique for parallel Monte Carlo simulation. A new filtering step in combination with correlated sampling avoids the disturbing noise artifacts common to Monte Carlo methods.
We present an algorithm for determining quadrature rules for computing the direct illumination of predominantly diffuse objects by high dynamic range images. The new method precisely reproduces fine shadow detail, is much more efficient as compared to Monte Carlo integration, and does not require any manual intervention.
Many rendering problems can only be solved using Monte Carlo integration. The noise and variance inherent with the statistical method efficiently can be reduced by stratification. So far only uncorrelated stratification methods were used that in addition depend on the dimension of the integration domain. Based on rank-1-lattices we present a new stratification technique that removes this dependency on dimension, is much more efficient by correlation, is trivial to implement, and robust to use. The superiority of the new scheme is demonstrated for standard rendering algorithms.
Monte Carlo & Beyond
(2002)
Image synthesis often requires the Monte Carlo estimation of integrals. Based on a generalized concept of stratification we present an efficient sampling scheme that consistently outperforms previous techniques. This is achieved by assembling sampling patterns that are stratified in the sense of jittered sampling and N-rooks sampling at the same time. The faster convergence and improved anti-aliasing are demonstrated by numerical experiments.
thesis deals with the investigation of the dynamics of optically excited (hot) electrons in thin and ultra-thin layers. The main interests concern about the time behaviour of the dissipation of energy and momentum of the excited electrons. The relevant relaxation times occur in the femtosecond time region. The two-photon photoemission is known to be an adequate tool in order to analyse such dynamical processes in real-time. This work expands the knowledge in the fields of electron relaxation in ultra-thin silver layers on different substrates, as well as in adsorbate states in a bandgap of a semiconductor. It contributes facts to the comprehension of spin transport through an interface between a metal and a semiconductor. The primary goal was to prove the predicted theory by reducing the observed crystal in at least one direction. One expects a change of the electron relaxation behaviour while altering the crystal’s shape from a 3d bulk to a 2d (ultra-thin) layer. This is due to the fact that below a determined layer thickness, the electron gas transfers to a two-dimensional one. This behaviour could be proven in this work. In an about 3nm thin silver layer on graphite, the hot electrons show a jump to longer relaxation time all over the whole accessible energy range. It is the first time that the temporal evolution of the relaxation of excited electrons could be observed during the transition from a 3d to a 2d system. In order to reduce or even eliminate the influence coming from the substrate, the system of silver on the semiconductor GaAs, which has a bandgap of 1.5eV at the Gamma-point, was investigated. The observations of the relaxation behaviour of hot electron in different ultra-thin silver layers on this semiconductor could show, that at metal-insulator-junctions, plasmons in the silver and in the interface, as well as cascading electrons from higher lying energies, have a huge influence to the dissipation of momentum and energy. This comes mainly from the band bending of the semiconductor, and from the electrons, which are excited in GaAs. The limitation of the silver layer on GaAs in one direction led to the expected generation of quantum well states (QWS) in the bandgap. Those adsorbate states have quantised energy- and momentum values, which are directly connected to the layer thickness and the standing electron wave therein. With the experiments of this work, published values could not only be completed and proved, but it could also be determined the time evolution of such a QWS. It came out that this QWS might only be filled by electrons, which are moving from the lower edge of the conduction band of the semiconductor to the silver and suffer cascading steps there. By means of the system silver on GaAs, and of the known fact that an excitation of electrons in GaAs with circularly polarised light of the energy 1.5eV does produce spin polarised electrons in the conduction band, it became possible to bring a contribution to the hot topic of spin injection. The main target of spin injection is the transfer of spin polarised electrons out of a ferromagnet into a semiconductor, in order to develop spin dependent switches and memories. It could be demonstrated here that spin polarised electrons from GaAs can move through the interface into silver, could be photoemitted from there and their spin was still being detectable. As a third investigation system, ultra-thin silver layers were deposited on the insulator MgO, which has a bandgap of 7.8eV. Also in this system, one could recognize a change in the relaxation time while reducing the dimension of the silver layer from thick to ultra-thin. Additionally, it came out an extreme large relaxation time at a layer thickness of 0.6 – 1.2nm. This time is an order of magnitude longer than at thick films, and this is a consequence of two factors: first, the reduction of the phase space due to the confined electron gas in the z-direction, and second, the slowlier thermalisation of the electron gas due to less accessible scattering partners.
A Topology Primer
(2002)