Abstract
The world is changing and demanding stronger, lighter, and more versatile materials. Taking advantage of the full potential of these materials also requires versatile manufacturing processes. The in situ forming of a liquid-infused preform (ISFLIP) is a new manufacturing process for fiber-reinforced polymer (FRP) parts with shell shapes. ISFLIP is a hybrid process between vacuum infusion (VI) and diaphragm forming. This paper focuses on the mechanical design and experimental validation of a functional prototype of ISFLIP. The novelty of the design lies especially in a double-diaphragm system that is fundamental to carrying out the forming just after the infusion stage. The double-diaphragm system and other two major subsystems, a vacuum table and an infrared heating grid, were devised to benefit from the operational advantages of ISFLIP. The whole prototype, once constructed, was tested by forming some demonstration components. The result of one of these components, a “C” cross-section FRP profile with two sharp joggles, is finally obtained, proving the feasibility of the prototype.
Issue Section:
Design Innovation Paper
References
1.
Holmes
, M.
, 2014
, “Global Carbon Fibre Market Remains on Upward Trend
,” Reinf. Plast.
, 58
(6
), pp. 38
–45
. 10.1016/S0034-3617(14)70251-62.
Soutis
, C.
, 2005
, “Fibre Reinforced Composites in Aircraft Construction
,” Prog. Aerosp. Sci.
, 41
(2
), pp. 143
–151
. 10.1016/j.paerosci.2005.02.0043.
Fuchs
, E. R. H.
, Field
, F. R.
, Roth
, R.
, and Kirchain
, R. E.
, 2008
, “Strategic Materials Selection in the Automobile Body: Economic Opportunities for Polymer Composite Design
,” Compos. Sci. Technol.
, 68
(9
), pp. 1989
–2002
. 10.1016/j.compscitech.2008.01.0154.
Bader
, M. G.
, 2002
, “Selection of Composite Materials and Manufacturing Routes for Cost-Effective Performance
,” Compos. Part A Appl. Sci. Manuf.
, 33
(7
), pp. 913
–934
. 10.1016/S1359-835X(02)00044-15.
Khan
, L. A.
, and Mehmood
, A. H.
, 2016
, “Cost-Effective Composites Manufacturing Processes for Automotive Applications,” Lightweight Composite Structures in Transport
, J.
Njuguna
, ed., Woodhead Publishing
, Cambridge, UK
, pp. 93
–119
.6.
Juan
, J.
, Salán
, N.
, and Tornero
, J. A.
, 2015
, “Sistema Y Procedimiento de Infusión de Resina Por Vacío Para La Obtención de Piezas Elaboradas a Partir de Materiales Compuestos
,” Spanish Patent No. 2,551,180 B2.7.
Juan
, J.
, 2017
, “Development of the In Situ Forming of a Liquid Infused Preform (ISFLIP) Process. A New Manufacturing Technique for High Performance Fibre Reinforced Polymer (FRP) Components
,” Ph.D thesis, Barcelona Tech
, Terrassa, Spain
.8.
Foley
, M. F.
, 1992
, “The Flexible Resin Transfer Molding (FRTM) Process
,” SAMPE J.
, 28
(6), pp. 15
–24
.9.
Thagard
, J. R.
, Okoli
, O. I.
, Liang
, Z.
, Wang
, H. P.
, and Zhang
, C.
, 2003
, “Resin Infusion Between Double Flexible Tooling: Prototype Development
,” Compos. Part A Appl. Sci. Manuf.
, 34
(9
), pp. 803
–811
. 10.1016/S1359-835X(03)00201-X10.
Zhang
, K.
, Gu
, Y.
, Zhang
, J.
, Li
, M.
, Wang
, S.
, and Zhang
, Z.
, 2015
, “Rapid Curing Vacuum-Assisted Resin Infusion Molding Using Silicone Rubber Sheet Heater and the Effect of Cooling Process on the Properties of Carbon Fiber/Epoxy Composites
,” J. Compos. Mater.
, 50
(13
), pp. 1837
–1850
. 10.1177/002199831559799011.
Thagard
, J. R.
, Okoli
, O. I.
, and Liang
, Z.
, 2004
, “Resin Infusion Between Double Flexible Tooling: Evaluation of Process Parameters
,” J. Reinf. Plast. Compos.
, 23
(16
), pp. 1767
–1778
. 10.1177/073168440404114812.
Fang
, X.
, Bi
, C.
, Hong
, Y.
, Cho
, K. H.
, Park
, M. S.
, Wang
, Y.
, and Yao
, D.
, 2016
, “Rapid Vacuum Infusion and Curing of Epoxy Composites With a Rubber-Cushioned Mold Design
,” Polym. Plast. Technol. Eng.
, 55
(10
), pp. 1030
–1038
. 10.1080/03602559.2015.113245313.
Mesogitis
, T. S.
, Skordos
, A. A.
, and Long
, A. C.
, 2014
, “Uncertainty in the Manufacturing of Fibrous Thermosetting Composites: A Review
,” Compos. Part A Appl. Sci. Manuf.
, 57
, pp. 67
–75
. 10.1016/j.compositesa.2013.11.00414.
Linke
, M.
, Greb
, C.
, Klingele
, J.
, Schnabel
, A.
, and Gries
, T.
, 2012
, “Automating Textile Preforming Technology for Mass Production of Fibre-Reinforced Polymer (FRP) Composites,” The Global Textile and Clothing Industry
, R.
Shishoo
, ed., Woodhead Publishing
, Cambridge, UK
, pp. 171
–195
.15.
Elkington
, M.
, Ward
, C.
, Chatzimichali
, A.
, and Potter
, K.
, 2015
, “Studying Effects of Preshearing on Hand Layup
,” Adv. Manuf. Polym. Compos. Sci.
, 1
(2
), pp. 80
–93
. 10.1179/2055035914Y.000000000716.
Belhaj
, M.
, Deleglise
, M.
, Comas-Cardona
, S.
, Demouveau
, H.
, Binetruy
, C.
, Duval
, C.
, and Figueiredo
, P.
, 2013
, “Dry Fiber Automated Placement of Carbon Fibrous Preforms
,” Compos. Part B Eng.
, 50
, pp. 107
–111
. 10.1016/j.compositesb.2013.01.01417.
Ashby
, M.
, Shercliff
, H.
, and Cebon
, D.
, 2007
, “Strategic Thinking: Matching Material to Design,” Materials: Engineering, Science, Processing and Design
, H.
Shercliff
, ed., Butterworth-Heinemann
, Oxford, UK
, pp. 29
–46
.18.
Diani
, J.
, Fayolle
, B.
, and Gilormini
, P.
, 2009
, “A Review on the Mullins Effect
,” Eur. Polym. J.
, 45
(3
), pp. 601
–612
. 10.1016/j.eurpolymj.2008.11.01719.
Taherian
, H.
, and Ramiar
, A.
, 2005
, “A Novel Technique for Radiation Shape Factor Calculation Using CAD Software
,” Numer. Heat Transf. Part B Fundam.
, 48
(4
), pp. 387
–403
. 10.1080/1040779059100929720.
Gupta
, M. K.
, Bumtariya
, K. J.
, Shukla
, H. A.
, Patel
, P.
, and Khan
, Z.
, 2017
, “Methods for Evaluation of Radiation View Factor: A Review
,” Mater. Today Proc.
, 4
(2
), pp. 1236
–1243
. 10.1016/j.matpr.2017.01.14321.
Govignon
, Q.
, Bickerton
, S.
, Morris
, J.
, and Kelly
, P. A.
, 2008
, “Full Field Monitoring of the Resin Flow and Laminate Properties During the Resin Infusion Process
,” Compos. Part A Appl. Sci. Manuf.
, 39
(9
), pp. 1412
–1426
. 10.1016/j.compositesa.2008.05.00522.
Govignon
, Q.
, Kazmi
, S. M. R.
, Hickey
, C. M. D.
, and Bickerton
, S.
, 2011
, “Control of Laminate Quality for Parts Manufactured Using the Resin Infusion Process
,” ICCM18: 18th International Conference of Composite Materials
, Jeju Island, Korea
, Aug. 21–26
.23.
Cao
, J.
, Akkerman
, R.
, Boisse
, P.
, Chen
, J.
, Cheng
, H. S.
, de Graaf
, E. F.
, Gorczyca
, J. L.
, Harrison
, P.
, Hivet
, G.
, Launay
, J.
, Lee
, W.
, Liu
, L.
, Lomov
, S. V.
, Long
, A.
, de Luycker
, E.
, Morestin
, F.
, Padvoiskis
, J.
, Peng
, X. Q.
, Sherwood
, J.
, Stoilova
, T.
, Tao
, X. M.
, Verpoest
, I.
, Willems
, A.
, Wiggers
, J.
, Yu
, T. X.
, and Zhu
, B.
, 2008
, “Characterization of Mechanical Behavior of Woven Fabrics: Experimental Methods and Benchmark Results
,” Compos. Part A Appl. Sci. Manuf.
, 39
(6
), pp. 1037
–1053
. 10.1016/j.compositesa.2008.02.01624.
Sachs
, U.
, Akkerman
, R.
, Fetfatsidis
, K.
, Vidal-Sallé
, E.
, Schumacher
, J.
, Ziegmann
, G.
, Allaoui
, S.
, Hivet
, G.
, Maron
, B.
, Vanclooster
, K.
, and Lomov
, S. V.
, 2014
, “Characterization of the Dynamic Friction of Woven Fabrics: Experimental Methods and Benchmark Results
,” Compos. Part A Appl. Sci. Manuf.
, 67
, pp. 289
–298
. 10.1016/j.compositesa.2014.08.02625.
Lin
, H.
, Long
, A. C.
, Sherburn
, M.
, and Clifford
, M. J.
, 2008
, “Modelling of Mechanical Behaviour for Woven Fabrics Under Combined Loading
,” Int. J. Mater. Form.
, 1
(1
), pp. 899
–902
. 10.1007/s12289-008-0241-726.
Alshahrani
, H.
, and Hojjati
, M.
, 2016
, “Influence of Double-Diaphragm Vacuum Compaction on Deformation During Forming of Composite Prepregs
,” J. Sci. Adv. Mater. Devices
, 1
(4
), pp. 1
–5
. 10.1016/j.jsamd.2016.09.00327.
ten Thije
, R.
, 2007
, “Finite Element Simulations of Laminate Composite Forming Processes
,” PhD thesis, Universiteit Twente
, Netherlands
.28.
ten Thije
, R. H. W.
, and Akkerman
, R.
, 2009
, “A Multi-Layer Triangular Membrane Finite Element for the Forming Simulation of Laminated Composites
,” Compos. Part A Appl. Sci. Manuf.
, 40
(6–7
), pp. 739
–753
. 10.1016/j.compositesa.2009.03.004Copyright © 2019 by ASME
You do not currently have access to this content.
