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Level 25

15 B - SHAPING PROCESSES FOR POLYMER MATRIX COMPOS


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Closed mold processes
TWO PART MOLDS CREATES A COMPOSITE PART, a process with good finish on all surfaces, higher production rates, better tolerance control, and the ability to produce more complex three-dimensional shapes, consist of the following processes: [1] Compression molding, [2] Transfer molding, [3] Injection molding. >>> TIC: TRANSFER, INJECTION, COMPRESSION
Compression molding PMC processes
COMPRESSION MOLDING PMC PROCESSES are based on the compression molding for polymers, pressing a charge of raw material into shape with a two part, heated mold, curing the polymer after molding.
Molding of molding compounds
COMPRESSION MOLD SHAPES A MOLDING COMPOUND INTO A DESIRED FORM, the sheet, bulk, thick molding compounds being refrigerated before use. Also has names such as SMC molding and BMC molding.
Preform molding
MOLD PUSHES FORTH A PLASTIC CHARGE TO IMPREGNATE A PRECUT FIBER MAT, using either thermosets or thermoplastics sheets or pellets, melting and driving them deep into the flesh of the mat.
Elastic reservoir molding
MOLD SQUEEZES TOGETHER A RESIN FILLED OPEN FOAM CORE AND TWO DRY FIBER LAYERS, creating a light and stiff and strong part, it's outer layer a shining armor of carbon.
Transfer molding PMC processes
WORKS ON SAME PRINCIPLE AS REGULAR TRANSFER MOLDING, differing in presence of short reinforcers in the injected thermoset resin, or by presence of continuous reinforcer fibers in the heated mold that cures the transfered resin, creating a strong, fiber reinforced part.
Injection molding PMC processes
INJECTION MOLDING OF SHORT FIBER REINFORCED THERMOSETS OR THERMOPLASTICS, a low cost, high rate production process, fit for very high production rates. NOZZLE ALIGNS INJECTED FIBERS.
Filament winding
MACHINE WINDS FIBERS ON ROTATING MANDREL, creating hollow shapes: storage tanks, hollow pipes, helicopter blades, winding layer after layer of continuous filaments either dry or soaked in resin, or by laying layer after layer of prepreg filaments, the partially cured resin creating a strong and stiff and resilient structure after curing.
Wet winding
Winding of resin soaked filaments.
Prepreg winding
Machine winds prepreg filaments with partially cured resin.
Postimpregnation
Machine winds dry fibers on mandrel; wage slave impragnates fibers with resin.
Winding direction
Helical, polar and biaxial winding. [1] Helical - machine winds filament around part in spiral pattern. [2] Polar - filament winds around long axis of mandrel. [3] bi-axial - combination of helical and polar winding.
Mandrel for filament winding
THE PART AROUND WHICH MACHINE WINDS FILAMENT, a part that has to be collapsible or inflatable, in order to remove them from the resulting cocoon of glassy fibers and stinking epoxy.
Pultrusion
STUPID MACHINE PULLS RESIN COATED FIBERS THROUGH A DIE, creating a great multitude of parts: rods, tubing, long and flat sheets, structural sections, while utilizing a variety of components such as epoxies, thermosets, polyesters and silicones, pulling the cured profile by rollers and cutting it to pieces if needed afterwards, a process consisting of five stages: [1] Filament feeding - the filaments are taken from the creel, [2] Resin impregnation - resin covers the filaments, [3] Pre-die forming - bestowing of initial shape to fibers, [4] Shaping and curing - pulling the resin filled filaments through a die shaping and curing them, [5] Pulling and cutting - rollers pull and saw cuts of the head.
Pullforming
Pulls and forms a curve part in a similar way to pultrusion, yet with an added step to give curvature to the final part.
Other PMC shaping processes
Other PMC shaping processes include: [1] Centrifugal casting, [2] Tube rolling, [3] Continuous Laminating, [4] Cutting methods >>> RoL CoC: ROLLING, LAMINATING,,, CENTRIFUGAL, CUTTING
PMC Centrifugal casting
Rotating drum cures polymer resin with short fibers.
Tube rolling
WAGE SLAVE ROLLS PREPREG SHEETS ON STEEL MANDREL, producing a nice and strong tube, curing it in an oven before he uses it to bash his own head in, splattering blood and bone and brains all over his workplace in a desperate and futile act of defying a cruel and senseless world, a world capable of producing a golden age for the whole humanity, yet so cruel and senseless that men are forced to work like beasts of burden
Continuous lamination
Dips corrugated fiber mats in resin, curing them in a continuous process.
Cutting methods
HARD CUTTING TOOLS FOR HARD COMPOSITES. Since cured composites are quite hard, wage slaves use hard cutting tools such as carbide and diamond tools, in addition to high speed steel saw blades, to cut composite materials to size. STRONG KNIFES CUT HARD COMPOSITES.