A Non-Geodesic Trajectory Design Method and Its Post-Processing for Robotic Filament Winding of Composite Tee Pipes

With the advantages of high specific strength and well corrosion resistance, polymer-matrix composite tee pipes are widely used in aerospace and civilian fields. The robotic filament winding technology is suitable for forming complex shape parts. This paper aims to provide a novel non-geodesic trajectory design method to get a continuous trajectory for tee pipe winding. Furthermore, post-processing methods are proposed for realizing the full coverage of tee pipes by robotic filament winding. The CAD/CAM software is then designed to simulate the winding process and realize the cover of the whole tee pipe. Finally, experiments of winding a tee pipe with a desktop winding machine and a six-axis winding robot are carried out. The results show that the tee pipe is fully covered, verifying the accuracy of the design method and post-processing methods.

Tribological Behavior of Phenolic Resin-Based Friction Composites Filled with Graphite

In this paper, the influence of graphite (Gr) on the dry sliding tribological properties of phenolic resin (PF) composites was studied under different sliding speeds of 3.1-47.1 m/s. The wear mechanism was investigated by the observation of the morphology of the transfer layer during the dry sliding process. It was found that the addition of Gr could decrease the friction coefficient and wear rate effectively, and the friction coefficient and wear rate decreased with the increase of Gr content in the range of 10-30 vol.%. The dominant wear mechanisms of PF-based friction composites changed from adhesive wear to fatigue wear (in the form of peeling-off) in the high sliding speed condition after the addition of Gr. The addition of Gr effectively reduced the sensitivity of PF-based friction materials to sliding speeds, and thus enhanced the stability of the friction coefficient. When the content of Gr was above 20 vol.%, the stability of the friction coefficient was relatively steady.

Modelling of Effective Thermal Conductivity of Composites Filled with Core-Shell Fillers

An effective model to calculate thermal conductivity of polymer composites using core-shell fillers is presented, wherein a core material of filler grains is covered by a layer of a high-thermal-conductivity (HTC) material. Such fillers can provide a significant increase of the composite thermal conductivity by an addition of a small amount of the HTC material. The model employs the Lewis-Nielsen formula describing filled systems. The effective thermal conductivity of the core-shell filler grains is calculated using the Russel model for porous materials. Modelling results are compared with recent measurements made on composites filled with cellulose microbeads coated with hexagonal boron nitride (h-BN) platelets and good agreement is demonstrated. Comparison with measurements made on epoxy composites, using silver-coated glass spheres as a filler, is also provided. It is demonstrated how the modelling procedure can improve understanding of properties of materials and structures used and mechanisms of thermal conduction within the composite.

Tribological Behaviour of Additively Manufactured Fiber-Reinforced Thermoplastic Composites in Various Environments

Polymer composites with increased utility properties are becoming competition for conventional materials, in conjunction with additive manufacturing techniques. The aim of this study was to evaluate tribological characteristics of fibrous composites produced in fused deposition modeling (FDM) with the use of an innovative head with symmetrical feeding of the matrix material. Analysis of the influence of composite-forming temperature on their tribological properties allowed the determining of the optimal printing process parameters for this group of composites. Significant differences in the friction process of the same reinforced materials were observed in dry and wet environments. Fibrous composites showed 10 times lower wear intensity as well as two times lower friction value in water than in air. Research shows friction in the water environment ensures more even wear of the surface of the composites involved in the work. The article contains 3D microscopic imaging of the friction plane of the tested composites and a description of a typical course of material wear is described.

The Impact of Halloysite on the Thermo-Mechanical Properties of Polymer Composites

Nanotubular clay minerals, composed of aluminosilicate naturally structured in layers known as halloysite nanotubes (HNTs), have a significant reinforcing impact on polymer matrixes. HNTs have broad applications in biomedical applications, the medicine sector, implant alloys with corrosion protection and manipulated transportation of medicines. In polymer engineering, different research studies utilize HNTs that exhibit a beneficial enhancement in the properties of polymer-based nanocomposites. The dispersion of HNTs is improved as a result of pre-treating HNTs with acids. The HNTs' percentage additive up to 7% shows the highest improvement of tensile strength. The degradation of the polymer can be also significantly improved by doping a low percentage of HNTs. Both the mechanical and thermal properties of polymers were remarkably improved when mixed with HNTs. The effects of HNTs on the mechanical and thermal properties of polymers, such as ultimate strength, elastic modulus, impact strength and thermal stability, are emphasized in this study.

Creep and Recovery Behaviour of Polyolefin-Rubber Nanocomposites Developed for Additive Manufacturing

Nanocomposite application in automotive engineering materials is subject to continual stress fields together with recovery periods, under extremes of temperature variations. The aim is to prepare and characterize polyolefin-rubber nanocomposites developed for additive manufacturing in terms of their time-dependent deformation behaviour as revealed in creep-recovery experiments. The composites consisted of linear low density polyethylene and functionalized rubber particles. Maleic anhydride compatibilizer grafted to polyethylene was used to enhance adhesion between the polyethylene and rubber; and multi-walled carbon nanotubes were introduced to impart electrical conductivity. Various compositions of nanocomposites were tested under constant stress in creep and recovery. A four-element mechanistic Burger model was employed to model the creep phase of the composites, while a Weibull distribution function was employed to model the recovery phase of the composites. Finite element analysis using Abaqus enabled numerical modelling of the creep phase of the composites. Both analytical and numerical solutions were found to be consistent with the experimental results. Creep and recovery were dependent on: (i) composite composition; (ii) compatibilizers content; (iii) carbon nanotubes that formed a percolation network.

Tailoring Material Stiffness by Filler Particle Organization

In the context of emerging methods to control particle organization in particle-matrix composite materials, we explore, using finite element analysis, how to modulate the material bulk mechanical stiffness. Compared to a composite containing randomly distributed particles, material stiffness is enhanced 100-fold when filler particles are aligned into linear chains lying parallel to the loading direction. In contrast, chains aligned perpendicular to that direction produce negligible stiffness change. These outcomes reveal how zigzag chains, which provide intermediate results, can modulate stiffness. The stiffness decreases gradually with increasing zigzag angle θ over a range spanning 2 orders of magnitude.