Minimizing corner cracking during the de-moulding process of industrial-size GFRP components: a case study
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ORIGINAL ARTICLE
Minimizing corner cracking during the de-moulding process of industrial-size GFRP components: a case study Bryn J. Crawford 1 & Juan Torres 1 & Abbas S. Milani 1 Received: 21 July 2020 / Accepted: 22 September 2020 / Published online: 3 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This article, through an industrial-level case study, presents workflows employed for decision-making to mitigate cracking of glass fibre reinforced polymer (GFRP) parts in tight radii corner locations, often resulting from displacement-controlled demoulding processes. Namely, using process simulation to evaluate the cure cycle of the GFRP composite parts, it was possible to optimize the time of de-moulding and reduce the potential for part damage. It was observed that the most significant factors influencing the corner defect were boundary conditions of the part during de-moulding, the workshop temperature and part thickness. The poorest process design case was identified as hot workshop temperature, a laminate with thickness on the upper end of tolerances and a boundary condition where most sides are free, allowing for the development of larger moment forces at the tight corners. Further to this, a de-moulding time chart was developed to account for the changes in material properties as a function of temperature and material thickness, allowing for the in situ decision-making of technicians to reduce the occurrence of corner cracks. Keywords Fibre reinforced polymers . Moulding . Part corner cracking . Process characterization . Simulation
1 Introduction Glass fibre reinforced polymers (GFRPs) have become increasingly popular materials of interest in construction, automotive, marine, sporting goods and other manufacturing industries [1, 2]. These cost-efficient composites offer advantages over classical material counterparts, such as metals and pure plastics, by allowing for the manufacture of near-net shape and lightweight parts with complex geometries [3, 4], along with a high-quality, glossy surface finish that can be resistant to corrosive environment during service. However, there are still complexities associated with manufacturing GFRP composite parts, due to the thermo-chemomechanical nature of the process, where part properties are developed (evolve) simultaneously with the geometrical form of the part. This, combined with a poor process control, can often yield non-conformant process outcomes and part
* Abbas S. Milani [email protected] 1
Composites Research Network-Okanagan Laboratory, School of Engineering, University of British Columbia, Kelowna, Canada
defects. Such complex and highly non-linear systems often require heuristic-based approaches in conjunction with white-box physics-based models [5, 6]. One known such example is the stress-induced cracking of GFRP components during the de-moulding stage, compromising structural integrity of the part and perceived surface quality [4].
1.1 De-moulding process and its complexity The de-moulding process in GFPR composi
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