Automated 3D Skeleton Winding Process for Continuous-Fiber-Reinforcements in Structural Thermoplastic Components

Beck, Björn; Tawfik, H. H.; Haas, Jonathan; Park, Y.-B.; Henning, Frank

doi:10.1007/978-3-662-60809-8_13

Cited by 7 publications

(10 citation statements)

References 3 publications

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“…However, the combination presents new design challenges which must be investigated and further understood. 5,6 Researchers have investigated manufacturing of 3D space frame structures from continuous fiber thermoset composites, 7,8,9,10 as well as overmolded reinforcements made by winding heated commingled fibers 2,3 or thermoplastic UD tape collected into a bundle. 11 These and similar continuous fiber tow reinforcements have been shown to provide significant strength improvement over traditional molded components, especially in tension, 12,13,14 however prediction of the performance is limited.…”

Section: And Difficulty Withmentioning

confidence: 99%

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Simulating performance of tow reinforced hybrid-molded composites

Miller

Månsson

2023

Journal of Thermoplastic Composite Materials

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A critical milestone to the adoption of 3D tow reinforced hybrid-molded structures is the development of design guidelines and analysis techniques for accurate performance modelling. The cross-sectional dimensions of the tow bundle leads to fiber length discrepancies between the inner fibers and the outer fibers which manifest as tow spreading and local fiber waviness. The effects of simulating the resulting fiber orientations and effective elastic properties is investigated by modelling a representative beam in tension and bending load cases and comparing to previous experimental results. Accounting for fiber waviness in tension demonstrated greatly improved part stiffness predictions. Spread tow bundles improved predicted strength and stiffness over simulations where tow was constrained to a uniform cross section. Increased tow reinforcement increased bending stiffness, but failure behavior was significantly influenced by the overmolding material.

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Section: And Difficulty Withmentioning

confidence: 99%

“…Continuous fiber tow reinforcements in hybrid-molded, thermoplastic composite structures are an emerging technology for providing lightweight, mass producible, structural components for industries such as automotive. 1,2 Traditional continuous fiber reinforced composite structures suffer from limited geometric design flexibility 3…”

Section: Introductionmentioning

confidence: 99%

Simulating performance of tow reinforced hybrid-molded composites

Miller

Månsson

2023

Journal of Thermoplastic Composite Materials

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“…The authors highlighted the considerations in designing the FW process, including the winding trajectory, the winding tool, the mold and the winding pattern. Beck et al used FW to fabricate a 3D fiber skeleton which is then overmolded through injection molding to form the final part [25]. The continuous fibers in the 3D skeleton are oriented strategically to be aligned to the load path.…”

Section: Filament Windingmentioning

confidence: 99%

Review: Filament Winding and Automated Fiber Placement with In Situ Consolidation for Fiber Reinforced Thermoplastic Polymer Composites

2021

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Fiber reinforced thermoplastic composites are gaining popularity in many industries due to their short consolidation cycles, among other advantages over thermoset-based composites. Computer aided manufacturing processes, such as filament winding and automated fiber placement, have been used conventionally for thermoset-based composites. The automated processes can be adapted to include in situ consolidation for the fabrication of thermoplastic-based composites. In this paper, a detailed literature review on the factors affecting the in situ consolidation process is presented. The models used to study the various aspects of the in situ consolidation process are discussed. The processing parameters that gave good consolidation results in past studies are compiled and highlighted. The parameters can be used as reference points for future studies to further improve the automated manufacturing processes.

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“…Furthermore, Akkerman et al [25] inserted a rod, fabricated by laminating continuous glass-fiber reinforced thermoplastic tape, into the mold cavity then it is overmolded with the long glass fiber-reinforced PP to decrease the high cost of some processing methods such as hot compression molding. The work conducted by Beck et al [56] presented a 3D skeleton winding technology (3DSW) manufacturing process and developed the 3D test specimen obtained by connection of three main components. Fundamental investigations of these structural components with overmolded fiber skeletons demonstrate the potential of continuous fibers in injection molded components made from PP and polyphenylene sulfide (PPS).…”

Section: Glass Fiber-based Overmolded Composite Productionmentioning

confidence: 99%

“…Carbon fibers are high-strength and highmodulus fibers with a carbon content of more than 90%. At present, the modulus of carbon fibers can reach 90-95% of the perfect graphite modulus (1025 GPa) [56,57]. It is resistant to high temperatures, friction, electrical conductivity, heat conduction, and corrosion [58][59][60][61].…”

Section: Carbon Fiber-based Overmolded Composite Productionmentioning

confidence: 99%