Optimization of process-induced residual stresses in automated manufacturing of thermoset composites

Ammar, Mohamed M.A.; Shirinzadeh, Bijan; Zhao, Pan; Shi, Yaoyao

doi:10.1016/j.ast.2022.107443

Cited by 6 publications

(4 citation statements)

References 40 publications

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“…The RSs were measured through the incremental hole-drilling method (IHDM). The IHDM was conducted in three stages, as detailed in [ 45 , 46 ]. A tiny hole was drilled in the area of interest, rosetta strain gauges were used to measure the induced strains, and finally the strains were calibrated numerically and the RSs were measured in the cutting direction.…”

Section: Measuring Residual Stressesmentioning

confidence: 99%

“…These levels of the drilling speed and feed rate were chosen to achieve the best performance for measuring the stresses based on the optimization work conducted in [ 47 ]. The drilling was conducted incrementally and the calibration coefficients were determined through finite element analysis (FEA), as detailed in [ 13 , 45 ].…”

Section: Measuring Residual Stressesmentioning

confidence: 99%

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On the Role of Damage Evolution in Finite Element Modeling of the Cutting Process and Sensing Residual Stresses

Ammar

Shirinzadeh

Elgamal

et al. 2022

Sensors

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This study focuses on the role of the damage evolution when estimating the failure behavior of AISI 1045 steel for sensing and measuring metal cutting parameters. A total of five Lagrangian explicit models are established to investigate the effect of applying damage evolution techniques. The Johnson–Cook failure model is introduced once to fully represent damage behavior, i.e., no damage evolution is considered, and as a damage initiation criterion in the remaining approaches. A fracture energy-based model is included to model damage propagation with different evolution rates. Temperature-dependent and temperature-independent fracture energy models are also investigated. Dry orthogonal cutting and residual stresses measurements of AISI 1045 are conducted for validation. The significance of the damage evolution is investigated using honed-tool and sharp-tool models. Including the damage evolution led to a prediction of higher workpiece temperatures, plastic strains, cutting forces, and residual stresses, with no clear differences between linear and exponential evolution rates. The role of damage evolution is more evident when temperature-dependent evolution models are used.

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Section: Measuring Residual Stressesmentioning

confidence: 99%

Section: Measuring Residual Stressesmentioning

confidence: 99%

On the Role of Damage Evolution in Finite Element Modeling of the Cutting Process and Sensing Residual Stresses

Ammar

Shirinzadeh

Elgamal

et al. 2022

Sensors

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“…The curing of binder system lays the foundation for excellent combustion and mechanical performance, structural integrity, and effective storage of enormous chemical energy in the solid propellants. 2 To control an optimal curing process, the curing temperature and curing time are the two key parameters, which can determine the curing cross-linking reaction and the mechanical and combustion properties. The higher temperature will accelerate the curing reaction and improve the production efficiency, but suffer the risk of safety of even explosion.…”

mentioning

confidence: 99%

“…Solid composite propellant is a multiphase mixture with binder-cured elastomer as the matrix, mixed with several chemical ingredients such as oxidizers and metal fuels. The curing of binder system lays the foundation for excellent combustion and mechanical performance, structural integrity, and effective storage of enormous chemical energy in the solid propellants . To control an optimal curing process, the curing temperature and curing time are the two key parameters, which can determine the curing cross-linking reaction and the mechanical and combustion properties.…”

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confidence: 99%

In Situ Monitoring of Curing Reaction in Solid Composite Propellant with Fiber-Optic Sensors

et al. 2023

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Curing activity in the preparation of solid composite propellants determines the performance of solid rocket motors in operation. Limited by the lack of effective monitoring tools, the complete curing behavior and thermal-induced curing kinetics are rarely disclosed. It is still a challenge to monitor in situ and in real-time the physical and chemical cross-linking reaction during the curing of propellant. Herein, we demonstrate a promising approach based on optical fiber capable of being implanted inside the propellant to monitor the internal stress evolution during the curing process, by taking hydroxyl-terminated polybutadiene propellant as an example. Attributed to the strain and temperature sensitivity of a pair of optical fiber gratings, the thermal-assisted physico-chemical cross-linking states of curing process have been demonstrated in detail. By tracking the stress-induced wavelength shifts of fiber gratings and calculating the curing mechanism function, the complete curing roadmap, including the viscous flow stage, gel stage, hardening stage can be clearly revealed, and the curing completion times are obtained as 154, 81, and 40 h, at the curing temperatures of 60, 70, and 80 °C, respectively. The apparent activation energy of this curing system obtained by calculation is 73.88 kJ/mol. This flexible fiber-based sensor provides an effective tool for unraveling the cure kinetic mechanism, and paves a universal pathway to guide the preparation and applications of versatile composite materials for solid rocket motors.

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Influence of Physico-Mechanical Factors on Residual Technological Stresses and Strains of Composite Panels

Kondratiev

Kovalenko

Nabokina

et al. 2023

Lecture Notes in Networks and Systems

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Optimization of process-induced residual stresses in automated manufacturing of thermoset composites

Cited by 6 publications

References 40 publications

On the Role of Damage Evolution in Finite Element Modeling of the Cutting Process and Sensing Residual Stresses

On the Role of Damage Evolution in Finite Element Modeling of the Cutting Process and Sensing Residual Stresses

In Situ Monitoring of Curing Reaction in Solid Composite Propellant with Fiber-Optic Sensors

Influence of Physico-Mechanical Factors on Residual Technological Stresses and Strains of Composite Panels

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