A review on stamp forming of continuous fibre-reinforced thermoplastics

Brooks, Richard A.; Wang, Hongyan; Ding, Zerong; Xu, Jie; Song, Qinghua; Liu, Haibao; Dear, John P.; Li, N.

doi:10.1016/j.ijlmm.2022.05.001

Cited by 12 publications

(8 citation statements)

References 100 publications

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“…It is assumed that entrapped air creates voids in the bundle. The shrinkage of the surrounding matrix material tears these voids open, leading to a larger cavity and therefore a higher void content in EP 2 [ 33 , 34 ]. A longer impregnation time can be considered for high-viscosity materials [ 13 , 14 , 17 ].…”

Section: Discussionmentioning

confidence: 99%

Investigation on the Influence of Process Parameters on the Mechanical Properties of Extruded Bio-Based and Biodegradable Continuous Fiber-Reinforced Thermoplastic Sheets

Lang,

Neitzel,

MohammadKarimi

et al. 2023

Polymers

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The use of bio-based and biodegradable matrix materials in fiber-reinforced polymers (FRPs) is an approach to reduce the consumption of fossil resources and the amount of polymer waste. This study aims to assess the influence of the process parameters on the resulting mechanical properties of extruded bio-based and biodegradable continuous fiber-reinforced thermoplastics (CFRTPs) in the form of sheets. Therefore, the impregnation temperature during the production of PLA/flax fiber composites is varied between 220 °C and 280 °C, and the consolidation pressure, between 50 bar and 90 bar. A design of experiments approach is used. Fiber contents of 28.8% to 34.8% and void contents of 6.8% to 15.5% are determined for the composites by optical measurements. To assess the mechanical properties, tensile tests are performed. Using the evaluation software Minitab, a strong negative influence of the consolidation pressure on the tensile modulus and the tensile strength is observed. Increasing the pressure from 50 bar to 90 bar results in a reduction in the tensile modulus of 50.7% and a reduction in the tensile strength of 54.8%, respectively. It is assumed that this is due to fibers being damaged by the external force exerted onto the materials during the consolidation process in the calender. The influence of the impregnation temperature on the mechanical properties cannot be verified.

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Section: Discussionmentioning

confidence: 99%

Investigation on the Influence of Process Parameters on the Mechanical Properties of Extruded Bio-Based and Biodegradable Continuous Fiber-Reinforced Thermoplastic Sheets

Lang,

Neitzel,

MohammadKarimi

et al. 2023

Polymers

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“…Quasi-isotropic laminates are employed in this study, using a non-woven short carbon fibre cloth, namely chopped strand mat (CSM). The use of a quasi-isotropic laminate alleviates the need to perform tests at multiple orientations, while short fibres are characteristic of recycled composite and, thus, require further investigation [24][25][26]. Three types of carbon fibre materials are investigated:…”

Section: Materials and Manufacturingmentioning

confidence: 99%

“…Recycled composite materials are characterised by short, non-continuous fibres [24]. This is in contrast with most virgin (i.e., non-recycled) composite materials, made of continuous fibres [25]. As such, there is a growing interest in the understanding of non-continuous carbon fibre to help bring recycled carbon fibre onto the market [26].…”

Section: Introductionmentioning

confidence: 99%

Recycled Carbon Fibre Composites in Automotive Manufacturing

Souppez

Pavar²

2023

IJAMM

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Article Recycled Carbon Fibre Composites in Automotive Manufacturing Jean-Baptiste R. G. Souppez 1, * , and Geethanjali S. Pavar 2 1 Department of Mechanical, Biomedical and Design Engineering, School of Engineering and Technology, College of Engineering and Physical Sciences, Aston University, Birmingham B4 7ET, UK. 2 Institute for Energy Systems, School of Engineering, University of Edinburgh, Edinburgh EH9 3JW, UK. * Correspondence: j.souppez@aston.ac.uk Received: 9 January 2023 Accepted: 22 February 2023 Published: 6 March 2023 Abstract: The contemporary need for lightweight and sustainable materials in automotive manufacturing has made recycled carbon fibre an attractive option. Yet, aspects such as the mechanical properties of short fibre composites need to be characterised to fully identify the capabilities and opportunities for recycled carbon fibre in the automotive industry. Consequently, this paper aims to ascertain the potential of recycled carbon fibre materials for automotive manufacturing by considering mechanical properties, design implications, and resulting costs and sustainability. Destructive testing is employed to characterise the mechanical properties of virgin carbon fibre (VCF), recycled carbon fibre (RCF) using pyrolysis, and blended recycled carbon fibre (BRCF) comprising 50% polypropylene fibre. Here we quantify (i) the reduction in mechanical properties, namely the tensile modulus and breaking strength, (ii) the resulting increase in required thickness and therefore mass for manufactured parts and (iii) the reduction in cost and embodied energy achieved for RCF and BRCF compared to VCF, based on both a stiffness- and a strength-driven design criterion. Furthermore, we present a decision-making methodology revealing BRCF as the most cost-effective solution, while RCF proves to be the most sustainable alternative. These results provide a novel quantitative assessment of recycled carbon fibre for automotive manufacturing and may contribute to future developments in sustainable composite manufacturing in the automotive industry.

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“…In production, flat preforms built up from individual UD tapes or fabrics can be formed into a geometry under heat and pressure within seconds. Overmolding the composite base structure in an injection molding process enables its functionalization with geometrically complex features [1][2][3][4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Rotation Bending Test Method and Characterization of Unidirectional Carbon Fiber-Reinforced Polycarbonate Tapes at Processing Temperatures

Laresser,

Miron,

Kracalik

et al. 2024

Polymers

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Bending is one of the dominant material deformation mechanisms that occurs during the forming process of unidirectional (UD) thermoplastic tapes. Experimental characterization of the bending behavior at processing temperatures is crucial to obtaining close-to-reality data sets for process analysis or material modeling for process simulation. The main purpose of this study is to characterize to a high degree of accuracy the temperature-dependent bending behavior of single and multi-ply specimens of carbon fiber-reinforced polycarbonate (PC/CF) UD tapes at processing temperatures, which implies a molten state of the thermoplastic matrix. The application of the rotation bending test using a customized fixture may come with systematic deviations in the measured moment that result from a pivot offset or an effective clearance that is unknown under realistic test conditions. The present research analyzes these effects with analytical methods, experimental investigations, and simulations using a finite element model. In this context, a compensation method for the toe-in effect is evaluated. With this approach, we were able to obtain reliable data and characterize the bending resistance within the desired processing window. The data reveal a major drop in bending resistance between 200 °C and 250 °C and a less significant decrease between 250 °C and 300 °C. Analysis of the thickness-normalized bending resistances indicates a non-linear relationship between specimen thickness and measured moment but an increasing shear-dominated characteristic at higher temperatures.

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A review on stamp forming of continuous fibre-reinforced thermoplastics

Cited by 12 publications

References 100 publications

Investigation on the Influence of Process Parameters on the Mechanical Properties of Extruded Bio-Based and Biodegradable Continuous Fiber-Reinforced Thermoplastic Sheets

Investigation on the Influence of Process Parameters on the Mechanical Properties of Extruded Bio-Based and Biodegradable Continuous Fiber-Reinforced Thermoplastic Sheets

Recycled Carbon Fibre Composites in Automotive Manufacturing

Analysis of the Rotation Bending Test Method and Characterization of Unidirectional Carbon Fiber-Reinforced Polycarbonate Tapes at Processing Temperatures

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