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• W2952203560 abstract "To produce lightweight structural parts in the aerospace industry, carbon fibre reinforced polymer (CFRP) have been the material of choice for several years. A-part from using composites for large structures, there is an interest in using composites at a smaller scale for parts that have complex intricate features. Conventional continuous fibres (CF) offer the highest mechanical properties but are difficult to form. On the other hand, parts can be injection moulded using lower fibre volume content, short fibres reinforced polymers, but they lack mechanical properties. Lying between these two extremes are randomly-oriented strand (ROS) composites. Randomly-oriented strands, a bulk moulding compound, offer the possibility to mould complex intricate features such as ribs, tight radii and moulded holes. This work investigated the processing of complex shapes using carbon/PEEK ROS composites. An instrumented fixture was developed to produce a lab scale complex part. From this investigation, the processing window of a rib feature was determined as the critical filling pressure was obtained for various processing temperatures and strand size. Filling pressure was found to depend on both the strand size of the ROS composite and the temperature at which it is processed at. In this case a smaller strand size processed at higher temperature would result in the lowest filling pressure. The complex composite part was tested mechanically using two methods. The short-beam strength of the rib section was evaluated as well as the general strength of the part through a component test. The main findings showed the strength of the composite to be independent of processing pressure. This suggests that critical filling pressure was sufficient in reaching maximal nominal mechanical properties for ribbed features. In addition, a void content analysis on the rib section was conducted using X-ray microtomography. A volumetric void content of the rib section was obtained for various processing conditions. The porosity of a rib processed at its critical filling pressure was found to be less than 1.2%. In addition, processing the complex part above its filling pressure showed potential for void reduction. The effect of knitlines on ROS composites was assessed on a flat panel and for the lab scale complex part. Merging flows fronts of ROS composites resulting in a knitline was found to be greatly detrimental to mechanical properties. The drop in mechanical properties was attributed to resin-rich regions and lack of overlapping strands at the knitline. Most notably was a tensile strength reduction of as much as 80 % for a flat panel with the presence of a knitline. Finally, a composite bracket using ROS composites was manufactured taking in consideration the findings from the lab scale investigation. The composite part was manufactured and tested demonstrating the weight benefits of this material.KEYWORDS: composites, randomly-oriented strands (ROS), compression moulding, complex parts.%%%%Aujourd'hui, les materiaux composites sont de plus en plus…" @default.
• W2952203560 created "2019-06-27" @default.
• W2952203560 creator A5066176243 @default.
• W2952203560 date "2015-01-01" @default.
• W2952203560 modified "2023-09-27" @default.
• W2952203560 title "Compression moulding of complex parts with randomly-oriented strand thermoplastic composites" @default.
• W2952203560 hasPublicationYear "2015" @default.
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