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Integrated Computational Material Design for PMC Manufacturing with Trapped Rubber.

Brina J Blinzler1, Pooria Khalili1, Johan Ahlström2

  • 1Division of Material and Computational Mechanics, Department of Industrial and Materials Science, Chalmers University of Technology, SE-412 96 Gothenburg, Sweden.

Materials (Basel, Switzerland)
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A new computational framework optimizes manufacturing for continuous fiber polymer matrix composites. This sustainable approach uses trapped rubber processing to improve component quality and reduce energy consumption in high-rate production.

Keywords:
compositeselastomersprocessingsimulationtrapped rubber processing

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Area of Science:

  • Materials Science and Engineering
  • Computational Material Design
  • Sustainable Manufacturing

Background:

  • Growing demand for sustainable manufacturing processes in polymer matrix composites.
  • Need for high-quality component production in high-rate manufacturing.
  • Limitations of current manufacturing methods for composites.

Purpose of the Study:

  • To develop an integrated computational material design framework for polymer matrix composites.
  • To enable the design of tailored, sustainable manufacturing systems.
  • To achieve high-quality components in high-rate production using novel methods.

Main Methods:

  • Development of an integrated computational material design framework.
  • Utilizing trapped rubber processing for high-pressure composite manufacturing.
  • Performing coupled thermo-mechanical analysis for process simulation.
  • Interdisciplinary approach combining structural analysis, material science, and manufacturing engineering.

Main Results:

  • The framework enables the design of tailored manufacturing systems for polymer matrix composites.
  • Trapped rubber processing achieves high pressures and custom pressure/temperature distributions.
  • Coupled thermo-mechanical analysis accurately simulates manufacturing transients.
  • Computed internal surface pressures and temperatures align with experimental data.

Conclusions:

  • The developed framework offers a sustainable alternative for manufacturing high-quality polymer matrix composite components.
  • Trapped rubber processing facilitates high-rate production with reduced energy consumption and improved throughput.
  • The integrated design loop ensures cohesive optimization of mold mechanics and manufacturing processes.
  • This approach maintains high-quality consolidation during curing while allowing for process customization.