Abstract

Multi-die thermoplastic pultrusion was showcased in previous studies to improve the impregnation quality of the pultrudate without significantly increasing the system’s pulling force. Using carbon-fibre and polyetherimide (PEI) commingled fibre, this study compares different die sequences using three taper angles and different die outlet area progressions. A modelling algorithm is proposed to predict the pulling force and degree of impregnation of a multi-die system. Concurrently, a methodology is developed to adjust the material characteristics of the model based on microstructure observations and single-die performance. The model predicts the degree of impregnation and pulling force generated by the multi-die sequence. The quality of pultrudate was supported by density measurement and characterization of inter-laminar shear strength. Predicted pulling forces and degree of impregnation agreed with experimental data produced for the sequences tested. The experimental observations highlight a significant difference in pulling force and degree of impregnation relationship which hints at an optimization opportunity.

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