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Manufacturing Simulation for Composites and Composite Structures

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: closed (20 June 2022) | Viewed by 4532

Special Issue Editor

Institute for Polymer Engineering, Lightweight Design & Composite Technologies, FHNW University of Applied Sciences and Arts Northwestern Switzerland, 5210 Windisch, Switzerland
Interests: composite; simulation; lightweight design; advanced manufacturing

Special Issue Information

Dear Colleagues,

Although composite materials have numerous advantages, they have some relevant disadvantages, including high manufacturing costs. Manufacturing process simulation can help to shift from an experimental trial and error approach towards a knowledge-based development of the manufacturing process.

The objective of this Special Issue is to present elements of a coherent virtual process chain for a composite structure manufacturing process which represents all physical effects leading to critical quality aspects such as process-induced deformations and stresses, filling/injection and curing, as well as draping errors.

Virtual process models and their connection to online process monitoring methods can enable feedback loops to enable “as-built” analysis and the comparison to “as planned” conditions. Uncertainty analysis, sensitivity analysis, and evaluation of the effects of defects are the focus of this Special Issue.

This Special Issue will cover recent advances in process simulation, and is open to all composite manufacturing processes.  

Submitted manuscripts will be fast-track reviewed. Research articles, review articles, perspectives and communications are invited.

Prof. Dr. Christian Braune
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • process-induced deformation
  • residual stresses
  • curing
  • crystallization
  • filling simulation
  • draping simulation
  • RTM, FDM, FFF, autoclave
  • as-built analysis
  • effect of defects

Published Papers (3 papers)

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Research

15 pages, 1915 KiB  
Article
Simulation Research on Continuous Concrete Beams Reinforced with External Prestressed CFRP Tendons
by Ning Duan, Ji-Wen Zhang and Jun Cheng
Materials 2022, 15(16), 5697; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15165697 - 18 Aug 2022
Cited by 1 | Viewed by 939
Abstract
This paper examines the effects of different loading patterns on the static characteristics of continuous concrete beams reinforced with external prestressed carbon fiber-reinforced polymer tendons (EPCFRPT) and qualitatively analyzes the results for two continuous concrete beams: SB-1 under symmetrical loading, and SB-2 under [...] Read more.
This paper examines the effects of different loading patterns on the static characteristics of continuous concrete beams reinforced with external prestressed carbon fiber-reinforced polymer tendons (EPCFRPT) and qualitatively analyzes the results for two continuous concrete beams: SB-1 under symmetrical loading, and SB-2 under asymmetrical loading. Then, a finite element analysis model is introduced and calibrated by tests conducted at Southeast University and data collected from a literature review. Based on the FEA model, the initial prestress, cross-section area, and eccentricity of CFRP tendons as well as the steel reinforcement configuration were selected by a parametric study. The results indicated that the initial prestress and tendon cross-section area had the most influence on the tendon stress increment and the secondary bending moment of the middle support, while the reinforcement distribution and eccentricity of the tendons had little effect. The secondary bending moment had a linear positive correlation with the stress increment of tendons. These results allow a simplified equation for calculating the external load bending moment amplitude coefficient at ultimate to be proposed. Full article
(This article belongs to the Special Issue Manufacturing Simulation for Composites and Composite Structures)
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20 pages, 5949 KiB  
Article
Influence of Cement Replacement with Sewage Sludge Ash (SSA) on the Heat of Hydration of Cement Mortar
by Elżbieta Haustein, Aleksandra Kuryłowicz-Cudowska, Aneta Łuczkiewicz, Sylwia Fudala-Książek and Bartłomiej Michał Cieślik
Materials 2022, 15(4), 1547; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15041547 - 18 Feb 2022
Cited by 18 | Viewed by 1890
Abstract
The amount of fly ash from the incineration of sewage sludge is increasing all over the world, and its utilization is becoming a serious environmental problem. In the study, a type of sewage sludge ash (SSA) collected directly from the municipal sewage treatment [...] Read more.
The amount of fly ash from the incineration of sewage sludge is increasing all over the world, and its utilization is becoming a serious environmental problem. In the study, a type of sewage sludge ash (SSA) collected directly from the municipal sewage treatment plant was used. Five levels of cement replacement (2.5%, 5%, 7.5%, 10% and 20%) and unchanged water-to-binder (w/b) ratio (0.55) were used. The purpose of the study was to evaluate the effect of sewage sludge ash (SSA) on the hydration heat process of cement mortars. The heat of the hydration of cement mortars was monitored by the isothermal calorimetric method for 7 days at 23 °C. The analysis of chemical composition and particle size distribution was performed on the tested material. The tests carried out have shown that SSA particles have irregular grain morphology and, taking into account the chemical composition consists mainly of oxides such as CaO, P2O5, SiO2 and Al2O3. The concentration of these compounds affects the hydration process of cement mortars doped with SSA. In turn, the content of selected heavy metals in the tested ash should not pose a threat to the environment. Calorimetric studies proved that the hydration process is influenced by the presence of SSA in cement mortars. The studies showed that the rate of heat generation decreased (especially in the initial setting period) with the increasing replacement of cement by SSA, which also reduced the amount of total heat compared to the control cement mortar. With increasing mass of the replacement of cement with SSA up to 20%, the 7-day compressive strength of the mortar samples decreases. Full article
(This article belongs to the Special Issue Manufacturing Simulation for Composites and Composite Structures)
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24 pages, 58515 KiB  
Article
Cost, Draping, Material and Partitioning Optimization of a Composite Rail Vehicle Structure
by Daniel Lang and Donald W. Radford
Materials 2022, 15(2), 449; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15020449 - 07 Jan 2022
Viewed by 1256
Abstract
This study proposes a novel methodology to combine topology optimization and ply draping simulation to partition composite structures, improve structural performance, select materials, and enable more accurate representations of cost- and weight-efficient manufacturable designs. The proposed methodology is applied to a structure as [...] Read more.
This study proposes a novel methodology to combine topology optimization and ply draping simulation to partition composite structures, improve structural performance, select materials, and enable more accurate representations of cost- and weight-efficient manufacturable designs. The proposed methodology is applied to a structure as a case study to verify that the methodology is effective. One design concept is created by subjecting the structure to a kinematic ply draping simulation to inform the partitioning of the structure, improve drapability and performance, and reduce structural defects. A second design concept is created that assumes that plies are draped over the entire structural geometry, forming an integral design. The two design concepts’ topologies are subsequently optimized to specify ideal material and ply geometries to minimize mass and reduce costs. The results indicate that the partitioned structure has a 19% lower mass and 15% lower material costs than the integral design. The two designs produced with the new methodology are also compared against two control designs created to emulate previously published methodologies that have not incorporated ply draping simulations. This demonstrates that neglecting the effects of ply draping produces topology optimization solutions that under-predict the mass of a structure by 26% and costs by 38%. Full article
(This article belongs to the Special Issue Manufacturing Simulation for Composites and Composite Structures)
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