| Author(s) |
Kamyar Gordnian, Alireza Forghani, DeWayne Howell, Alberto Mussali, Alastair McKee, Malcom Lane, Goran Fernlund, Anoush Poursartip |
| Abstract Scope |
Thermoplastic composites are increasingly recognized in aerospace, automotive, and energy sectors for their benefits, including fast manufacturing, automation, adoption of conventional metal processing methods, repairability, recyclability, and extended shelf life. Despite these advantages, challenges arise, such as elevated processing temperatures, increased matrix viscosity, material degradation, and potential process-induced defects like lack of consolidation, delamination, and wrinkles. Process simulation has become critical for understanding the impact of process parameters on the final product state, thereby mitigating manufacturing risks and costs. The accuracy and effectiveness of process simulation rely on material models that capture the evolution of material state during processing, serving as mathematical representations of various phenomena of interest. This paper provides an overview of Toray Cetex® TC1225 thermoplastic composite characterization for process simulation. The characterization includes aspects such as crystallization/melt kinetics, modulus development/relaxation, thermal expansion, and crystallization shrinkage. Using Convergent’s COMPRO process simulation platform, the crystallinity distribution, along with process-induced deformations of a thermoplastic part in a hot press process, is predicted. Validation of simulation results against experimental measurements provides valuable insights for optimizing thermoplastic composite manufacturing processes. |