MANUFACTURING

PROCESS OF PMC
SUBMITTED BY
PRACHI AGRAHARI
ROLL NO.- 31
 Processing
types

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mold mold

Filament
Pultrusion
winding
• Broad principle of any processing technique that is used for processing of
polymer matrix composites is that we have to combine the fibre and the
matrix(polymer) together.
• Here the fibre is the reinforcing agent and the polymer is the matrix that
provides the bulk to composite materials.
 Pultrusion process

 Commercialy used for processing of parts which is having uniform cross

section.
 So it is long product manufacturing process, length of product is not a
limitation in case of pultrusion process.
 Because of continuous fibre reinforcement ,strength of product is very good.
 Developed around 1950 for making fishing rods of glass fibre reinforced
polymer(GFRP)
 Meaning of Pultrusion

 In Extrusion process we push the molten plastic by the rotation of the screw
through the nozzle,into the dye then it comes out as a continuous cross
section profile.
 In pultrusion process the basic principle will remain the same but how fibres
can also be added along with the polymer and how the product is coming out
of the dye.
 Material is pulled out of the dye unlike in extrusion process hence the name
pultrusion.
Raw materials
• Reinforcement
Type: E-Glass,S-Glass,carbon/graphite,aramid
Form: roving,mat,fabric
• Matrix: Polyesters,polyvinyl esters,epoxy resins.
Steps followed during Pultrusion process

1. Reinforcement handling system(creel)

2. Resin impregnation station
3. Material forming area
4. Components that heat and consolidate
5. Equipment to pull pultruded part
6. Equipment to cut pultruded part
Pultrusion set-up
 Advantages of pultrusion
 High throughput rate(mass production)
 High material usage(low process waste)
 Able to use wide variety of reinforcement types,forms and
styles with many thermosetting resins
 Complex thin walled shapes can be fabricated
 Can fabricate extremely large/long parts
 Can fabricate any transportable length parts
Disadvantages/Limitation of pultrusion
 Cross-sections must generally be uniform
 Difficult to maintain tight tolerances
 Quick curing resin systems typically have lower
mechanical properties
 Complexity of process- problems resulting from resin and
fibres accumulating and building up at die entrance
 Parts are run resin rich to account for fibre anomalies,
strength is sacrificed
 Voids may result in parts if excessive opening given at die
entrance
 Filament winding
 Filament winding process is used for the production of
composite product with high fibre volume fractions and
controlled orientation.
 It is composite processing technique in which resin
impregnated fibres are wound over a rotating mandrel at
the specific orientation.
 The process is suitable for production of cylindrical
shaped composite parts.
 Commercial process because machines are available off
hand in the market
 Now a days computer controlled machines are used which
independently monitor every movement of the whole
process and thus leading to production of complex
geometries.
 Well known and established process for thermosetting
polymers(viscous form)
 Different movements
 movement is the rotation of fibre creel
 Movement of fibre
 Linear Movement of carriage as well as the rotation of
mandrel
we have to synchronise this movement to avoid
damage/defective product
Filament winding set-up
 Raw materials used in the system
• Reinforcing materials
Glass fibre(E and S-glass), carbon fibre,kevlar fibre, boron
fibre,aramid fibre (all this fibres are in straight filament
directly coming from creel. Any kind of woven mat or
stitched into a fabric form are not used in filament winding)
• Matrix
epoxy, polyester, polyvinylester
 Various main component
 Fibre creel
 Resin impregnated system
 Carriage
 Rotating mandrel
 Important controlling parameters
 Fibre tension
 Winding speed(rotation of mandrel)
 Design of resin bath
 Viscosity of resin
 Winding pattern
 Carriage movement
Fibre tension is most critical parameter
 Fibre tension
 Compaction is achieved through the fibre tension
 Fibre tension affects the percentage of fibre
reinforcement and porosity content in the composite
 Fibre tension depends upon the type of fibre, its geometry
and the winding pattern
 Too high fibre tension may break the fibre completely or
initiate fibre fracture at the surface
 Advantages
 High strength to weight ratio is possible to achieve with
this process
 High degree of uniformity in fibre distribution,orientation
and placement
 Lobor involvement is minimal as it is automated process
 Filament winding method is suitable to process composite
parts requiring precise tolerances
 Fibres orientation in a specific direction is possible in this
process
 Design flexibility in composite part is possible with the
change in the winding pattern, material and curing option
 The size of the composite is not restricted
 For high production volume,process automation results in
cost saving
 Cost of the composite part is processed through the
filament winding method is substantially low as compared
to other manufacturing methods as it involves less and low
cost material to produce high strength component
Disadvantages
 Capital investment is relatively high
 Very precise control over the mechanism is required for
uniform distribution and orientation of fibre
 Composite product configuration be such that it should
facilitate in mandrel extraction
 Applications
 Composite products like storage tanks,pipelines, vessels,
gas cylinders, fishing rods, missile cases, rocket motor
cases, ducting, cement mixture, aircraft fuselage and golf
club shaft are very common to be developed with this
method
 Now, the application spectrum of filament winding has
expanded to complex engineered no spherical and non
cylindrical compositeproductswith the use of sophisticated
machinery and software.
THANKYOU!