Pultrusion of solid thermoplastic composite rods from commingled yarns with diameters up to Ø 40 mm.
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Multi-physics FE model simulating the temperature distribution and evolution during pultrusion.
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In-situ observation of novel batch-pultrusion process via a transparent die.
Abstract
Pultrusion is a rapid and cost-effective manufacturing technology for continuous fibre reinforced thermoplastic composite profiles. As the cross-sections of pultruded profiles grow to meet increasing performance requirements, manufacturing challenges concerning heat transfer are encountered. In this study, a two-dimensional finite element model was used to simulate the heat transfer and fluid flow physics of the pultrusion process for increasing diameters from Ø 5–Ø 40 mm. To facilitate the experimental validation, a novel batch-wise pultrusion concept is introduced in which the impregnation process is observed in-situ using a transparent die. The pultrusion studies, conducted on glass-fibre/amorphous polyethylene terephthalate (GF/PET) commingled yarns, show that – with proper design – pultrusion is able to deliver consistent, high quality (void content < 2%) profiles up to at least Ø 40 mm.