Thermoforming of foam sheet

Thermoforming is a widely used process for the manufacture of foam sheet products. Polystyrene foam food trays for instance can be produced by first heating the thermoplastic foam sheet, causing the gas contained to build up pressure and expand, after which a vacuum pressure can be applied to draw the sheet in the required form on the mould. This production method appears to be a very sensitive process with respect to e.g. the sheet temperature, the pressures applied and the cooling time. More problems can be foreseen when for environmental reasons the blowing agent will be adapted (for instance replaced by a gas with a lower molecular weight). To gain more insight in the occuring phenomena the large deformations of a foam structure have been analysed using finite element modelling. To this end a constitutive model has to be defined. Starting from the basic theory given by Gibson & Ashby [1], the behaviour of a closed cubic cell has been elaborated for large strains. The total stiffness is then the sum of the contributions of the edges and faces of the cell and the gas contained in it. The large deformations cause anisotropy of the cells [2], which influences their tangential stiffness. The constitutive model developed here includes the effects of internal gas pressure and the evolving anisotropy

Towards modelling of the frictional behaviour of deforming fibrous tows: A\ud geometrical approach

Fibrous tows used in continuous fibre-reinforced polymers (CFRPs) deform\ud geometrically during the production of composite products. The cross-sectional\ud geometry of the tow is influenced by the load-induced deformation mechanisms. A\ud study of the effect of two commonly assumed geometrical tow shapes on an\ud equivalent pressure distribution in a tow-on-a-pin spreading arrangement was\ud performed. The preliminary results show that both elliptic and parabolic tow\ud geometries have qualitatively the comparable equivalent pressure distributions

Actuators for smart applications

Actuator manufacturers are developing promising technologies\ud which meet high requirements in performance, weight and\ud power consumption. Conventionally, actuators are characterized\ud by their displacement and load performance. This hides the\ud dynamic aspects of those actuation solutions. Work per weight\ud performed by an actuation mechanism and the time needed to\ud develop this mechanical energy are by far more relevant figures.\ud Based on these figures, a selection process was developed.\ud With time and energy constraints, it highlights the most\ud weight efficient actuators. This process has been applied to the\ud Gurney flap technology used as a morphing concept for rotorblades.\ud Three control schemes were considered and simulations\ud were performed to investigate the mechanical work required. It\ud brought forward piezoelectric stack actuators as the most effective\ud solution in the case of an actively controlled rotorblade. The\ud generic nature of the procedure allows to use it for a wide range\ud of applications

Development of a multigrid finite difference solver for benchmark permeability analysis

A finite difference solver, dedicated to flow around fibre architectures is currently being developed. The complexity of the internal geometry of textile reinforcements results in extreme computation times, or inaccurate solutions. A compromise between the two is found by implementing a multigrid algorithm and analytical solutions at the coarsest level of discretisation. Hence, the computational load of the solver is drastically reduced.\ud This paper discusses the main features of the 3D multigrid algorithm implemented as well as the implementation of the analytical solution in the finite difference scheme. The first tests of the solver on the permeability benchmark lithographic reference geometry are discussed.\ud Several tests were performed to assess the accuracy and the reduction in calculation time. The methods prove to be both accurate and efficient. However, the code is developed in Matlab© and hence is relatively slow. A C++ code is currently under development to achieve acceptable calculation times

Warpage of rubber pressed composites

The rubber pressing process is applied for the rapid production of thermoplastic composite products. However, rubber pressed products show geometrical distortions, such as warpage, due to process-induced residual stresses. It is believed that these stresses build up as a result of the large thermal gradients that are present during consolidation. An experimental study is performed to measure the curvature after rubber pressing of initially flat woven fabric glass/PPS composite panels. A material model is proposed that incorporates the solidification of the composite in order to predict the residual stresses and the warpage due to inhomogenous cooling. The model is employed in Finite Element simulations of the rubber pressing process. The simulations are compared to the experimentally obtained curvatures. It shows that inhomogeneous cooling has a minor effect on the warpage in this case, and that another mechanism is present