UNLV Retrospective Theses & Dissertations 1-1-1998 The cooling of a pultrusion process simulator Fredericka Delores Brown University of Nevada, Las Vegas Follow this and additional works at: https://digitalscholarship.unlv.edu/rtds Repository Citation Brown, Fredericka Delores, "The cooling of a pultrusion process simulator" (1998). UNLV Retrospective Theses & Dissertations. 912. http://dx.doi.org/10.25669/ufpp-zdhj This Thesis is protected by copyright and/or related rights. It has been brought to you by Digital Scholarship@UNLV with permission from the rights-holder(s). You are free to use this Thesis in any way that is permitted by the copyright and related rights legislation that applies to your use. For other uses you need to obtain permission from the rights-holder(s) directly, unless additional rights are indicated by a Creative Commons license in the record and/ or on the work itself. 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NOTE TO USERS The original manuscript received by UMI contains broken or light print. All efforts were made to acquire the highest quality manuscript from the author or school. Page(s) were microfilmed as received. This reproduction Is the best copy available UMI Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. THE COOLING OF A PULTRUSION PROCESS SIMULATOR by Fredericka D. Brown Bachelor of Science Xavier University of Louisiana 1996 A thesis submitted in partial fulfillment of the requirements for the degree of Master of Science in Mechanical Engineering Department of Mechanical Engineering University of Nevada, Las Vegas August 1998 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. UMI Number: 1392316 UMI Microform 1392316 Copyright 1998, by UMI Company. All rights reserved. This microform edition is protected against unauthorized copying under Titie 17, United States Code. UMI 300 North Zeeb Road Ann Arbor, MI 48103 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. 1998 Fredericka D. Brown All Rights Reserved Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Thesis Approval UNTV The Graduate College University of Nevada, Las Vegas JULY 24 19 98 The Thesis prepared by FREDERICKA D. BROWN Entitled THE COOLING OF A PULTRUSION PROCESS SIMULATOR is approved in partial fulfilment of the requirements for the degree of MASTER OF SCIENCE IN MECHANICAL ENGINEERING A Examination Committee Chair Dean of the Cnfduite College ticm Committee Member tion CommL tee Member U Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. ABSTRACT The Cooling of a Pultrusion Process Simulator by Fredericka D. Brown Dr. Robert Boehm, Examination Committee Chair Professor of Mechanical Engineering University of Nevada, Las Vegas Experimental and numerical modeling was done to analyze the thermal processes, focusing on the cooling rates, that occurred in a simulated representation of a composite material manufacturing process. The simulation apparatus was constructed similar to that of a compression molding device to represent the thermal process of the pultrusion machine. The simulation block utilized temperature variations and compaction pressure to create small samples that represented sections from a pultruded geometry. In this study, the thermal performance of this device was analyzed utilizing a numerical model. The effect of cooling passages and their location in the simulation block was also analyzed. The numerical results were then compared with the experimental measurements of sample centerline temperature, ambient temperature, die surface temperature, and die surface heat loss. Measured values were then compared with the initial predicted values. Experimental modeling was then done on the pultrusion machine which gave the transient temperature field experienced by a standard cross-section of material being pultruded. Comparisons ui Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. were then made between the two types of experimental measurements and numerical estimates. Conclusions were drawn about the ability of the simulant device to match the thermal conditions of the pultrusion machine, in particular the cooling rate, found in the actual pultrusion process. IV Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. TABLE OF CONTENTS ABSTRACT ................................................................................................................. iii LIST OF FIGURES ................................................................................................... vii ACKNOWLEDGMENTS ............................................................................................ x CHAPTER I INTRODUCTION ..........................................................................1 CHAPTER 2 EXPERIMENTAL APPARATUS ...............................................7 Pultrusion Machine ....................................................... 7 Pultrusion Simulator Block ...........................................9 CHAPTER 3 EXPERIMENTAL PROCEDURE .............................................11 Pultrusion Machine .......................................................11 Pultrusion Simulator Block ........................................ 12 CHAPTER 4 NUMERICAL PROCEDURE ................................................... 13 CHAPTERS RESULTS AND ANALYSIS ................................................... 17 Pultrusion Machine ...................................................... 17 Pultrusion Simulator Block ........................................24 Numerical Model ........................................................26 CHAPTER 6 CONCLUSIONS ......................................................................... 57 APPENDIX I COMPOSITE MATERIALS ..................................................... 59 APPENDDC n CARBON/PEEK COMPOSITE FIBERS .................................64 APPENDIX m MANUFACTURING METHODS OF COMPOSITE MATERIALS ............................................................................ 66 APPENDIX IV DIAGRAMS RELATED TO THE PULTRUSION SIMULATOR BLOCK AND ITS ANALYSIS ............................................ 70 APPENDIX V EQUATIONS DERIVED FOR USAGE IN THE NUMERICAL MODEL ...................................................................................... 71 APPENDIX VI GRID NETWORKS USED IN NUMERICAL M ODEL 74 APPENDIX Vn PULTRUSION MACHINE AND SIMULATION DEVICE .......77 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. APPENDIX Vin FORTRAN 77 PROGRAMS USED IN NUMERICAL MODELING ............................................................................80 REFERENCES ............................................................................................................. 123 VITA ...............................................................................................................................125 VI Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. LISTOFHGURES Figure 1 An experimental representation of cooling rate in pultruded carbon/PEEK fiber with a pull speed of 6 inches/minute and a consolidation temperature of 370°C ......................................................................................................18 Figure 2 An experimental representation of cooling rate