The document summarizes two manufacturing processes for polymer matrix composites: pultrusion and filament winding. Pultrusion involves pulling reinforced material through a die to produce continuous profiles with uniform cross-sections. It is well-suited for high-volume production. Filament winding involves winding resin-impregnated fibers onto a rotating mandrel to produce cylindrical or complex shapes. Both processes precisely orient and consolidate fibers and resins to produce high-strength, fiber-reinforced composite parts.
The document summarizes two manufacturing processes for polymer matrix composites: pultrusion and filament winding. Pultrusion involves pulling reinforced material through a die to produce continuous profiles with uniform cross-sections. It is well-suited for high-volume production. Filament winding involves winding resin-impregnated fibers onto a rotating mandrel to produce cylindrical or complex shapes. Both processes precisely orient and consolidate fibers and resins to produce high-strength, fiber-reinforced composite parts.
The document summarizes two manufacturing processes for polymer matrix composites: pultrusion and filament winding. Pultrusion involves pulling reinforced material through a die to produce continuous profiles with uniform cross-sections. It is well-suited for high-volume production. Filament winding involves winding resin-impregnated fibers onto a rotating mandrel to produce cylindrical or complex shapes. Both processes precisely orient and consolidate fibers and resins to produce high-strength, fiber-reinforced composite parts.
The document summarizes two manufacturing processes for polymer matrix composites: pultrusion and filament winding. Pultrusion involves pulling reinforced material through a die to produce continuous profiles with uniform cross-sections. It is well-suited for high-volume production. Filament winding involves winding resin-impregnated fibers onto a rotating mandrel to produce cylindrical or complex shapes. Both processes precisely orient and consolidate fibers and resins to produce high-strength, fiber-reinforced composite parts.
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MANUFACTURING
PROCESS OF PMC SUBMITTED BY PRACHI AGRAHARI ROLL NO.- 31 Processing types
Close Open Others 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!
