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PLASTICS (FRP)
Submitted by,
Menon Lakshmi Suresh
Divya C S
Amrutha K S
Lini cleetus C
Fiber Reinforced Polymer (FRP)
Composites are defined as:
• REINFORCEMENTS
• FILLERS
• ADDITIVES
• PRIMARY FUNCTION:
“TO TRANSFER STRESS BETWEEN
REINFORCING FIBERS AND TO PROTECT
THEM FROM MECHANICAL AND
ENVIRONMENTAL DAMAGE”
• TYPES:
– THERMOSET
– THERMOPLASTIC
THERMOSET THERMOPLASTIC
POLYESTER ACETAL
EPOXY NYLON
POLYETHYLENE
TEREPHTHALATE (PET)
• Intermediate length fiber reinforcement
– The longer the fibers, the more difficult it is to coat the fibers
enough to reap strength benefits
– Low viscosity thermosets “wet-out” the materials better than high
viscosity thermoplastics
– Generally use unsaturated polyester and vinylester resins for
FRP
Polyester resins
Epoxy resins
Phenolic resins and other thermo set resins
• impregnating preformed dry reinforcement in a
closed mold with wet thermosetting resin under
pressure
• production rate comparison
– 2 - 8 pph (parts per hour)
– spray-up 0.5 pph
– SMC, injection molding 30 pph (chopped
fibers,
high pressures requires >>$ tooling)
REINFORCEMENTS RESINS
type Polyester
E-glass, S-glass
carbon/graphite vinyl ester
aramid
form
mat epoxy
fabric
textile preform architecture
(knitted, braided, 3-D stitched)
preforms - preshaping of
reinforcement
• resin/curing agent (catalyst) mixing equipment
– positive displacement piston pumping cycle
– maintain accurate ratio control between resin and curing
agent
– RTM process requires low injection pressures (30 psi - 100
psi)
– piston type positive displacement pumps are critical due to
changing back pressure conditions - as resin is pushed
through reinforcement an increasing back pressure builds
against metering pumps - if slippage occurs at pump,
resin/curing agent ratio will be affected
• with resin system components accurately metered,
sent through flexible hoses to a mix head
• gasket around perimeter
• inlet injection port
– located at the lowest point of mold
– plug or check valve incorporated
• vent ports located at highest point of mold
• for high volume, tightly toleranced parts may use
press - controls parallelism of mold set during
opening and closing and holds mold closed
during injection (alternative is manually clamping
or fastening)
• may or may not take place under vacuum (assists in
minimizing air entrapment)
• mixer/injection head is inserted into mold
• injection pressure pushes check valve off its seat and
allows resin to begin filling
• air is pushed ahead of resin
• resin will begin flowing from vent ports
– if part design is simple may be full
– if part design complex, may require slight overfill to vent all
air
• vent ports are pinched off and internal pressure
causes inlet check valve to close
• critical to control infusion rate and flow front of
resin so that it infiltrates fiber preform evenly and
completely, but quickly before gelling
• resin is injected in center of part to guard against
formation of air pockets and minimize distance
resin must travel
• care must be exercised to insure reinforcement
does not move during injection (fiber wash)
ADVANTAGES DISADVANTAGES
- -Greater
Tooling Design and
Faster Production
Construction Skills Required
Labor Savings Higher Tool Cost
Truck pannel
boat hulls
Aerospace parts
Filament Winding (one-step process)
-very high rate process
-Amenable to automated machine control
(little labor required)
-pressure bottle and cylindrical shapes
-rapidly growing variety applications
-continuous roving/yarns/strands
-Continuous filaments wound a mandrel(tool)
Major concerns in filament windings shaft 27
-Resin selection
-Viscosity
-Need diluent or heat to lower viscosity
-Curing requirements
Fiber Requirements
-high tensile strength
-highest mechanical quality
-finishes to improve handling
REINFORCEMENTS RESINS
-continuous fiber over the entire part -mandrel could be complex and expensive
high fiber volume is obtainable
-inability to wind reverse curvature
-ability to orient fibers in the load direction
-inability to easily change fiber path within
-fiber and resin used in lowest cost form one layer
-Lack of ductility
Characteristics
-Pultrusion produces parts with
-high fiber volume, high percentage of unidirectional
reinforcement.
-primarily a method for thermosetting resins
-one of few continuous FRP process
-Accounts for 3% of total FRP
-based on continuous fibers
Process Steps:
-String-up of desired fiber pattern
-Resin impregnation
-Preforming shape around mandrel (if necessary)
-Pre-heat (augmented cure)
-Cut finished part to length
-Speed: 0.5 to 10 ft/min
-Throughput: up to 4 lb/min
36
RESINS REINFORCEMENTS
polyesters type
vinyl ester E-glass, S-glass
Epoxies(aromatic carbon/graphite
amine, anhydride aramid
cures) form
roving
mat
fabric
ADVANTAGES DISADVANTAGES
-High output; very long parts are -difficult to maintain tight tolerances
possible
-quick curing resin systems typically
-Uses inexpensive forms of have lower mechanical properties
reinforcement
-complexity of process
-Selective placement of reinforcement
relatively easy
-Low scrap
• Truck & bus components, such as body panels
and drive shaft
• Construction members such as building panels,
window & door frames, beams,pipes,cable trays
etc.
• Electrical equipment such as ladders,booms for
cherry picker trucks,tool handles etc.
• Sporting goods such as ski poles & fishing rods
Matched-die moulding
-The composite material is pressed between
heated matched dies
-Pressure required depends on the flow
characteristics of the feed materials
- The feed materials flows into the contours of the
mould and cures at high temp.
• Matched die or Compression molding
– Reduced flow path over injection or extrusion
– SMC compression molding allows for continuous
fibers, mats or weaves
– These processes offer parts that are finished on both
sides where most other composite processes do not
RIM utilizes highly reactive two-component resins that are low-viscosity
liquids at room temperature
To initiate mixing and injection,the piston in the mixhead moves up and the
two resin components collide in the mixing chamber under high speed and
high pressure
The resin streams collide at 100-200m/s resulting in pressures of 10-40MPa
Following mold filling, the piston purges the mixhead of remaining resin
Since crosslinking is initiated by mixing and is very rapid,the resin gels
within seconds after the mold has been filled,paertially aided by heating of
the mould
To ensure complete crosslinking,it is important that exactly correct
proportions of resin components are mixed
• Reinforced Reaction Injection Molding (RRIM) is
a process used to produce polyurethane and
polyurea thermoset polymers
• In RRIM short fibers are added to one of the
resin components prior to final resin mixing
• It has proved difficult to include fibers longer
than 0.5mm, since this leads to a too high
viscosity
• Although even such short fibers provide
significantly increased stiffness, damage
tolerance, dimensional tolerance and lower CTE
over what RIM components may offer, articles
produced through RRIM nevertheless have poor
structural properties from a composite view point
• This process is mainly used in automative
industry, where short cycle times and low labour
cost is important
• A subset of RIM is structural reaction injection molding (SRIM), which
uses fiber meshes for the reinforcing agent. The fiber mesh is arranged
• SRIM is used for long series where the significantly higher initial cost