Heat Analysis of Thermal Conductive Polymer Composites: Reference Temperature History in Pure Polymer Matrices

Area of Science:

• Materials Science
• Manufacturing Engineering
• Polymer Science

Background:

• Thermal conductive polymer (TCP) composites are vital in aerospace applications.
• Understanding heat generation during manufacturing is crucial for material performance and tool longevity.

Purpose of the Study:

• To assess heat generation in nonreinforced and glass-fiber-reinforced TCP composites during abrasive milling.
• To investigate the influence of fiber orientation on temperature profiles and material failure modes.

Main Methods:

• Prepared glass/epoxy and glass/polyester composites with 30% unidirectional glass fiber content.
• Recorded temperature histories using Type K thermocouples during abrasive milling.
• Performed Scanning Electron Microscopy (SEM) to analyze material failure modes.

Main Results:

• Milling parallel to glass fibers resulted in lower peak temperatures than in nonreinforced polymers due to reduced interfacial friction.
• Milling perpendicular to fibers led to significantly higher peak temperatures because of increased contact area and friction.
• SEM analysis revealed microcracks and debris contributing to heat generation, with failure modes varying by fiber orientation.

Conclusions:

• Fiber orientation critically affects heat generation during the abrasive milling of TCP composites.
• Optimizing milling strategies based on fiber orientation is essential for managing heat, ensuring surface finish integrity, and extending tool life.
• Effective heat conduction management is key to the economic viability of manufacturing processes involving these advanced composites.